Mainshaft Disassembly/Inspection/Reassembly

Disassembly/Inspection/Reassembly

NOTE:
- Lubricate all parts with ATF during reassembly.
- Inspect the thrust needle bearings and the needle bearings for galling and rough movement.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.

Mainshaft 3rd Gear Removal








1. Remove the mainshaft 3rd gear, 4th gear, and thrust washer, 43 x 74 mm from the mainshaft using the special tool and a press as shown.

Inspection

NOTE:
- Inspect and adjust the 43 x 74 mm thrust washer when disassembling the mainshaft assembly or replacing mainshaft 3rd gear and/or 1st/4th clutch assembly.
- Lubricate all parts with ATF during assembly.








1. Install mainshaft 3rd gear on the mainshaft using the special tool and a press as shown.





2. Assemble the thrust needle bearing, needle bearing, and 4th gear, then install the 43 x 74 mm thrust washer using the special tool and a press as shown.

NOTE: Replace the 43 x 74 mm thrust washer if you can install it by pressing it with your hand.





3. Spin the mainshaft 4th gear by hand to check for clearance. The clearance is normal if the gear turns freely without binding.
4. Remove the mainshaft bearing from the transmission housing.





5. Assemble the parts on the mainshaft.

NOTE: Do not install the O-rings and the mainshaft 1st gear on the mainshaft during inspection.





6. Torque the mainshaft locknut to 29 Nm (3.0 kgf-m, 22 ft. lbs.)
7. Move the 1st/4th clutch assembly to check the axial clearances.





8. Measure the clearance between the 1st/4th clutch guide and 1st gear collar with a feeler gauge.
STANDARD: 0 - 0.08 mm (0 - 0.003 inch)

NOTE: Take measurements in at least three places, and use the average as the actual clearance.





9. If the clearance is out of tolerance, remove the 43 x 74 mm thrust washer, and measure its thickness.

NOTE: If the 0.08 mm (0.003 inch) feeler gauge can be inserted, perform this step.

10. Select and install a new 43 x 74 mm thrust washer, then recheck the clearance.





THRUST WASHER, 43 x 74 mm





11. After replacing the 43 x 74 mm thrust washer, make sure that the clearance is within the tolerance.

Sub-assembly





NOTE:
- Lubricate all parts with ATF during assembly.
- Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.
- Assemble the mainshaft sub-assembly when assembling the transmission.
- Refer above when installing the 3rd gear, 4th gear, and 43 x 74 mm thrust washer.