Part 1

TRANSMISSION HOUSING
Removal

NOTE:
- If the transmission housing or clutch housing are replaced, the bearing preload must be adjusted.
- Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench.

1. Remove the shift arm cover assembly.





2. Remove the reverse idler gear shaft bolt.
3. Remove the setting screws, then remove the washers, springs, and steel balls.





4. Remove the back-up light switch.
5. Remove the 10 mm boltsand8mm bolts in a crisscross pattern in several steps.





6. Remove the 32 mm sealing bolt.
7. Expand the snap ring on the countershaft ball bearing, and remove it from the groove using a pair of snap ring pliers.
8. Separate the transmission housing from the clutch housing, and wipe it clean of the sealant.





9. Remove the 78 mm shim and oil guide plate, then remove the oil gutter plate.

REVERSE SHIFT FORK
Clearance Inspection





1. Measure the clearances between the reverse shift fork and 5th/reverse shift piece pin.





2. If the clearances are more than the service limit, measure the widths of the groove in the reverse shift fork.
- If the widths of the grooves are not within the standard, replace the reverse shift fork with a new one.
- If the widths of the grooves are within the standard, replace the 5th/reverse shift piece with a new one.





3. Measure the clearance between the reverse idler gear and reverse shift fork.





4. If the clearance is more than the service limit, measure the width of the reverse shift fork.
- If the width is not within the standard, replace the reverse shift fork with a new one.
- If the width is within the standard, replace the reverse idler gear with a new one.

REVERSE IDLER GEAR
Removal





1. Remove the reverse shift fork.





2. Remove the reverse idler gear shaft and the reverse idler gear.

MAINSHAFT, COUNTERSHAFT
Removal





1. Remove the mainshaft and countershaft assemblies with the shift forks from the clutch housing.

NOTE: Tape the mainshaft splines before removing the mainshaft and countershaft assemblies.





2. Remove the differential assembly.

MAINSHAFT ASSEMBLY





Index

NOTE:
- The 3rd/4th, and 5th synchro hubs, and the ball bearing are installed with a press.
- Install the angular ball bearing with the thin-edge outer race facing the taper cone ring.

Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. The 3rd/4th and 5th synchro hubs, however, should be installed with a press before lubricating them.

Clearance Inspection

NOTE: If replacement is required, always replace the synchro sleeve and hub as a set.

1. Support the bearing inner race with a socket, and push down on the mainshaft.





2. Measure the clearance between 2nd and 3rd gears.





3. If the clearance is more than the service limit, measure the thickness of 3rd gear.
- If the thickness of 3rd gear is less than the service limit, replace 3rd gear with a new one.
- If the thickness of 3rd gear is within the service limit, replace the 3rd/4th synchro hub with a new one.





4. Measure the clearance between 4th gear and the spacer collar.





5. If the clearance is more than the service limit, measure distance on the spacer collar.





6. If distance (6) is less than the service limit, replace the spacer collar with a new one. If distance (A) is within the service limit, measure the thickness of 4th gear.
- If the thickness of 4th gear is less than the service limit, replace 4th gear with a new one.
- If the thickness of 4th gear is within the service limit, replace the 3rd/4th synchro hub with a new one.





7. Measure the clearance between the spacer collar and 5th gear.





8. If the clearance is more than the service limit, measure distance & on the spacer collar.





9. If distance (j) is less than the service limit, replace the spacer collar with a new one.

If distance (b) is within the service limit, measure the thickness of 5th gear.
- If the thickness of 5th gear is less than the service limit, replace 5th gear with a new one.
- If the thickness of 5th gear is within the service limit, replace the 5th synchro hub with a new one.

Disassembly





1. Remove the ball bearing using a bearing puller as shown.

CAUTION: Remove the synchro hubs using a press and steel blocks as shown. Use of a jaw-type puller can cause damage to the gear teeth.





2. Support 5th gear on steel blocks, and press the mainshaft out of the 5th synchro hub, as shown.





3. In the same manner as above, support the 3rd gear on steel blocks, and press the mainshaft out of the 3rd/4th synchro hub, as shown.

Inspection





1. Inspect the gear surface and bearing surface for wear and damage, then measure the mainshaft at points A, B, and C.

If any part of the mainshaft is less than the service limit, replace it with a new one.





2. Inspect for runout.

Standard: 0.02 mm (0-0008 inch) max.
Service Limit: 0.05 mm (0.002 inch)

NOTE: Support the mainshaft at both ends as shown.

If the runout is more than the service limit, replace the mainshaft with a new one.

Reassembly





1. Support 2nd gear on steel blocks, then install the 3rd/4th synchro hub using the special tools and a press as shown.

NOTE: After installing, check the operation of the 3rd/4th synchro hub set.





2. Install the 5th synchro hub using the special tools and a press as shown.





3. Install the angular ball bearing in the direction shown using the special tools and a press.

COUNTERSHAFT ASSEMBLY





Index
Before assembling, clean all parts in solvent, dry them with compressed air, then coat them with clean oil.

Clearance Inspection





1. Measure the clearance between 1st gear and the thrust washer.





2. If the clearance exceeds the service limit, measure the thicknesses of 1st gear and the thrust washer.
- If the thicknesses of 1st gear and the thrust washer are less than the standard, replace them with new ones.
- If the thicknesses of 1st gear and the thrust washer are within the standard, replace the 1st/2nd synchro hub with a new one.





3. Measure the clearance between 2nd gear and 3rd gear.





4. If the clearance exceeds the service limit, measure the thicknesses of 2nd gear and the spacer.
- If the thicknesses of 2nd gear and the spacer are less than the standard, replace them with new ones.
- If the thicknesses of 2nd gear and the spacer are within the standard, replace the 1st/2nd synchro hub with a new one.

Disassembly





1. Securely clamp the countershaft assembly in a bench vise with wood blocks.
2. Raise the locknut tab from the groove in the countershaft, then remove the locknut and the spring washer.





3. Remove the ball bearing using a press as shown.





4. Remove the friction damper from the spacer using a press and a socket as shown.

Inspection





1. Inspect the gear surface and bearing surface for wear and damage, then measure the countershaft at points A, B, and C.

If any part of the countershaft is less than the service limit, replace it with a new one.





2. Inspect for runout.

Standard: 0.02 mm (0.0008 inch) max.
Service Limit: 0.05 mm (0.002 inch)

NOTE: Support the countershaft at both ends as shown.

If the runout exceeds the service limit, replace the countershaft with a new one.

Reassembly





1. Install the thrust washer, needle bearing, 1st gear, friction damper, synchro ring, and synchro spring.

NOTE: Reassemble the 1st gear and friction damper before installation.





2. Install the 1st/2nd synchro hub by aligning the friction damper fingers with 1st/2nd synchro hub grooves.





3. Install the friction damper on the spacer using the special tools and a press as shown.





4. Install the needle bearing and the ball bearing using a special tool and a press as shown.





5. Install the spring washer.

6. Securely clamp the countershaft assembly in a bench vise with wood blocks.

7. Tighten the new locknut to the correct torque, then stake the locknut tab into the groove.

Torque: 127 -> 0 -> 127 Nm (13 -> 0 -> 13 kgf-m, 94 -> 0 -> 94 ft. lbs.)


SHIFT FORK ASSEMBLY
Disassembly/Reassembly





Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts.

Clearance Inspection

NOTE: The synchro sleeve and synchro hub should be replaced as a set.





1. Measure the clearance between each shift fork and its matching synchro sleeve.





2. If the clearance is more than the service limit, measure the thickness of the shift fork fingers.
- If the thickness of the shift fork finger is not within the standard, replace the shift fork with a new one.
- If the thickness of the shift fork finger is within the standard, replace the synchro sleeve with a new one.





3. Measure the clearance between the shift fork and the shift arm.





4. If the clearance is more than the service limit, measure the width of the shift arm.
- If the width of the shift arm is not within the standard, replace the shift arm with a new one.
- If the width of the shift arm is within the standard, replace the shift fork or shift piece with a new one.