---===SME_1007_00055_0001.djvu===--- 22-1 GROUP 22 MANUAL TRANSMISSION (TRANSMISSION POWER TAKE-OFF) STRUCTURE AND OPERATION ...................................................... 22-2 TROUBLESHOOTING ........................................................................ 22-3 TRANSMISSION POWER TAKE-OFF (PTO) ..................................... 22-4 For other details except for the items described above, please refer to Shop Manual Chas- sis, Group 22 MANUAL TRANSMISSION, Pub. No. TWSE0415. ---===SME_1007_00055_0001.djvu===--- 22-1 GROUP 22 MANUAL TRANSMISSION (TRANSMISSION POWER TAKE-OFF) STRUCTURE AND OPERATION ...................................................... 22-2 TROUBLESHOOTING ........................................................................ 22-3 TRANSMISSION POWER TAKE-OFF (PTO) ..................................... 22-4 For other details except for the items described above, please refer to Shop Manual Chas- sis, Group 22 MANUAL TRANSMISSION, Pub. No. TWSE0415. ---===SME_1007_00055_0002.djvu===--- 22-2 Transmission Power Take-off (PTO) The transmission PTO takes out the power when the shift sleeve engages the PTO output gear, and delivers the engine power as it is. The shift sleeve is moved by the pis- ton stroke and the stroke is caused by the vacuum. STRUCTURE AND OPERATION ---===SME_1007_00055_0003.djvu===--- 22 22-3 Symptoms Reference Gr Possible causes PTO body abnormal Shift bar bent O O Shift fork bent O O Engagement gear of output gear and shift sleeve worn or damaged OO Bearings worn or damaged O O O Transmission oil insufficient O Gears broken or worn O Gear backlash excessively large O Gear backlash excessively small O Vacuum chamber faulty OOOO PTO control system faulty Transmission PTO switch faulty O O Gr54 Blowout of fuse and high-current fuse O O Gr54 Battery overcharge O Gr54 PTO control switch faulty O O Gr54 PTO relay faulty OO Gr54 3-way magnet valve faulty OOO Gr54 Clutch switch faulty OO Gr54 Broken wire, poor connection or faulty indicator O Gr54 Air leakage in vacuum piping O OO TROUBLESHOOTING ---===SME_1007_00055_0004.djvu===--- 22-4 TRANSMISSION POWER TAKE-OFF (PTO) ---===SME_1007_00055_0005.djvu===--- 22 22-5 Disassembly sequence Assembly sequence Follow the disassembly sequence in reverse. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Lubricant and/or sealant Location Maintenance item Standard value Limit Remedy 7, 9, 10 Play of input gear in axial direction 0.3 to 0.5 0.7 Replace 6, 8, 9 Play of input gear in diametrical direction 0.02 to 0.04 0.06 Replace 20, 21, 23 Play of output gear in axial direction 0.3 to 0.5 1 Replace 17, 21, 22 Play of output gear in diametrical direction 0.02 to 0.04 0.06 Replace 2, 19 Clearance between shift sleeve and shift fork 0.5 to 0.7 1 Replace Mark Parts to be tightened Tightening torque Remarks Nut (transmission PTO mounting) 50 {5.1} -- Nut (oil pump mounting) 85 {8.7} -- Plug 110 {11.2} -- Bolt (shift unit mounting) 30 {3.1} -- Stud bolt 110 {11.2} -- Mark Points of application Specified lubricant and/or sealant Quantity O-ring Wheel bearing grease [NLGI No. 2 (Li soap)] As required Lip area of oil seal Shaft spline where pump is installed Screw thread Loctite 270 As required 1 Plug 2 Shift unit (See later section.) 3 Gasket 4 Screw 5 O-ring 6 Input shaft 7 Friction washer 8 Needle bearing 9 Input gear 10 Axial disc 11 Adjusting nut 12 Spacer bush 13 Gasket 14 Oil seal 15 Circlip 16 Ball bearing 17 Adapter shaft 18 Race 19 Shift sleeve 20 Splined bush 21 Output gear 22 Needle bearing 23 Washer 24 Rubber plug 25 Circlip 26 Needle bearing 27 Case 28 Gasket 29 Spacer flange <M027S5> 30 Gasket <M027S5> 31 Stud bolt : Non-reusable parts ---===SME_1007_00055_0006.djvu===--- 22-6 Work before disassembly Inspection: Play of input gear in axial direction Measure the play of the input gear in axial direction. If the measured value exceeds the limit, replace the defective parts. Inspection: Play of output gear in axial direction Measure the play of the output gear in axial direction with the shift unit removed. If the measured value exceeds the limit, replace the defective parts. Inspection Procedure Inspection: Clearance between shift sleeve and shift fork Measure the clearance between the shift sleeve and the shift fork of the shift unit. If the measured value exceeds the limit, replace the defective parts. See "Shift unit" when disassembling the shift fork. Inspection: Play of input gear in diametrical direction Measure the play of the input gear in diametrical direction with the input shaft, the needle bearing, and the input gear assem- bled. If the measured value exceeds the limit, replace the defective parts. Inspection: Play of output gear in diametrical direction Measure the play of the output gear in diameter direction with the shaft, the needle bearing, and the output gear assembled. If the measured value exceeds the limit, replace the defective parts. TRANSMISSION POWER TAKE-OFF (PTO) ---===SME_1007_00055_0007.djvu===--- 22 22-7 Assembly procedure Assembly: Adjusting nut Tighten or loosen the adjusting nut so that the play of input gear in axial direction conforms to the specified value. Turn the indented hole on the adjusting nut to the side of the mating face with the transmission case. Tap the indented hole on the nut by a punch to prevent the nut from loosing. Confirm that the input gear rotates without resistance. ---===SME_1007_00055_0008.djvu===--- 22-8 Shift unit Disassembly sequence Assembly sequence Follow the disassembly sequence in reverse. Service standards (Unit: mm) Tightening torque (Unit: N·m {kgf·m}) Location Maintenance item Standard value Limit Remedy -- Piston operating force (when the vacuum pressure is 67 kPa {500 mmHg}) 98 N {10kgf} or more -- Replace -- Airtightness of shift unit 60 kPa {450 mmHg} -- Replace 11 Spring load (installed length: 41) 53to54 51 Replace Mark Parts to be tightened Tightening torque Remarks Nipple 35 {3.6} -- Switch 40 {4.1} -- Bolt (piston mounting) 30 {3.1} -- 1 Nipple 2 Switch (See Gr54.) 3 Air filter 4 Circlip 5 O-ring 6 End cover 7 O-ring 8 Piston 9 Screw 10 Bar 11 Spring 12 Spacer 13 Shift fork 14 Circlip 15 Axial disc 16 Oil seal 17 Cap 18 Oil seal 19 Housing :Non-reusable parts TRANSMISSION POWER TAKE-OFF (PTO) ---===SME_1007_00055_0009.djvu===---