Part 1
TRANSMISSION HOUSINGRemoval
1. Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench.
2. Remove the back up light switch, neutral position switch, reverse lockout solenoid, differential speed sensor and Vehicle Speed Sensor (VSS).
3. Remove the sealing bolts, springs and steel balls.
4. Remove the transmission housing attaching bolts in a crisscross pattern in several steps.
5. Remove the 36 mm sealing bolt.
6. Expand the snap ring on the countershaft ball bearing, and remove it from the groove using a pair of snap ring plier.
7. Separate the clutch housing from the transmission housing.
8. Remove the thrust shim and oil guide plate from the transmission housing.
REVERSE SHIFT ARM, REVERSE SHIFT FORK
Clearance Inspection
1. Measure the clearance between the reverse shift arm and the reverse shift piece.
Standard: 0.06 - 0.30 mm (0.002 - 0.012 inch)
Service Limit: 0.5 mm (0.02 inch)
2. If the clearance exceeds the service limit, measure the width of the groove in the reverse shift arm.
Standard: 7.05 - 7.20 mm (0.278 - 0.283 inch)
If the width of the groove exceeds the standard, replace the reverse shift arm with a new one. If the width of the groove is within the standard, replace the reverse shift piece with a new one.
3. Measure the clearance between the reverse shift arm and reverse shift fork.
Standard: 0.05 - 0.35 mm (0.002 - 0.014 inch)
Service Limit: 0.5 mm (0.02 inch)
4. If the clearance exceeds the service limit, measure the width of the reverse shift arm.
Standard: 12.8 - 13.0 mm (0.504 - 0.512 inch)
If the width is less than the standard, replace the reverse shift arm with a new one. If the width is within the standard, replace the reverse shift fork with a new one.
5. Measure the clearance between the reverse shift fork and reverse synchro sleeve.
Standard: 0.45 - 0.65 mm (0.018 - 0.026 inch)
Service Limit: 1.0 mm (0.039 inch)
6. If the clearance exceeds the service limit, measure the thickness of the shift fork fingers.
Standard: 6.4 - 6.5 mm (0.252 - 0.256 inch)
If the trickiness is less than the standard, replace the reverse shift fork with a new one. If the trickiness is within the standard, replace the reverse synchro sleeve with a new one. The synchro sleeve and synchro hub should be replaced as a set.
REVERSE IDLER GEAR SHAFT ASSEMBLY
Removal
1. Remove the reverse shift arm from the clutch housing.
2. Shift the reverse shift fork to the driven gear side.
3. Remove the reverse shift fork assembly.
4. Remove the reverse idle gear shaft assembly.
Disassembly/Reassembly
NOTE:
- The thrust needle bearings are the same size.
- The needle bearings are the same size.
Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surface.
REVERSE SHIFT FORK ASSEMBLY
Disassembly/Reassembly
NOTE: The spring pin grooves should be 180° apart.
Disassembly:
Remove the 3 mm spring pin and 5 mm spring pin.
Reassembly:
Install the 5 mm spring pin first, then install the 3 mm spring pin.
MAINSHAFT, COUNTERSHAFT, DIFFERENTIAL ASSEMBLIES
Removal
1. Remove the change holder assembly from the clutch housing.
2. Tape the mainshaft splines to protect them, then remove the mainshaft assembly and countershaft assembly with the shift fork from the clutch housing.
3. Remove the differential assembly from the clutch housing.
SHIFT LEVER, SELECT LEVER
Removal
1. Remove the shift spring set plate and shift detent spring from the transmission housing.
2. Remove the bolt and spring washer.
3. Pull out the shift lever, then remove the shift arm.
4. Remove the bolt and spring washer.
5. Pull out the select lever, then remove the select arm.
CHANGE HOLDER ASSEMBLY
Disassembly/Reassembly
NOTE: Make sure the return springs are installed properly.
Prior to reassembling, clean all parts in solvent, dry them, and apply lubricant to any contact surfaces.
CHANGE HOLDER ASSEMBLY, SHIFT FORK
Clearance Inspection
1. Measure the clearance between the shift piece and shift arm.
Standard: 0.05 - 0.25 mm (0.002 - 0.010 inch)
Service Limit: 0.5 mm (0.020 inch)
2. If the clearance exceeds the service limit, measure the width of the shift arm.
Standard: 12.9 - 13.0 mm (0.508 - 0.512 inch)
If the width of the shift arm is less than the standard, replace the shift arm with a new one. If the width of the shift arm is within the standard, replace the shift piece with a new one.
3. Measure the clearance between the interlock and select arm.
Standard: 0.03 - 0.15 mm (0.001 - 0.006 inch)
4. If the clearance exceeds the standard, measure the width of the interlock finger.
Standard: 11.95 - 12.00 mm (0.470 - 0.472 inch)
If the width of the interlock is less than the standard, replace the interlock with a new one. If the width of the interlock is within the standard, replace the select arm with a new one.
5. Measure the clearance between the shift fork and shift piece.
Standard: 0.2 - 0.5 mm (0.008 - 0.020 inch)
Service Limit: 0.6 mm (0.024 inch)
6. If the clearance exceeds the service limit, measure the width of the shift piece.
Standard: 11.9 - 12.0 mm 10.469 - 0.472 inch)
If the width of the shift piece is less than the standard, replace the shift piece with a new one. If the width of the shift piece is within the standard, replace the shift pieces or shift forks with a new one.
SHIFT FORK, SYNCHRO SLEEVE
Clearance Inspection
1. Measure the clearance between each shift fork and its matching synchro sleeve,
Standard: 0.45 - 0.65 mm 10.018 - 0.026 inch)
Service Limit: 1.0 mm (0.039 inch)
2. If the clearance exceeds the service limit, measure the width of the shift fork fingers.
Standard:
1st/2nd Shift Fork: 8.9 - 9.0 mm (0.350 - 0.354 inch)
3rd/4th,5th/6th Shift Fork: 7.4 - 7.5 mm (O.291 - 0.295 inch)
If the width of the shift fork fingers is less than the standard, replace the shift fork with a new one. If the width of the shift fork fingers is within the standard, replace the synchro sleeve with a new one. The synchro sleeve and synchro hub should be replaced as a set.
SHIFT FORK ASSEMBLY
Disassembly/Reassembly
NOTE: Install the spring pins so their grooves are 1800 apart.
Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces.
Disassembly: Remove the 3 mm spring pin and 5 mm spring pin.
Reassembly: Install the 5 mm spring pin first, then install the 3 mm spring pin.
MAINSHAFT ASSEMBLY
Index
NOTE: The 3rd/4th and 5th/6th synchro hubs are installed with a press.
Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. The 3rd/4th and 5th/6th synchro hubs, however, should be installed with a press before lubricating them.
Clearance Inspection
1. Measure the clearance between 2nd and 3rd gears.
Standard: 0.06 - 0.19 mm (0.002 - 0.007 inch)
Service Limit: 0.3 mm (0.012 inch)
2. If the clearance exceeds the service limit, measure the thickness of 3rd gear.
Standard: 30.39 - 30.47 mm (1.196 - 1.200 inch)
Service Limit: 30.30 mm (1.193 inch)
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.
3. Measure the clearance between 4th gear and the spacer collar.
Standard: 0.06 - 0.19 mm (0.002 - 0.007 inch)
Service Limit: 0.3 mm (0.012 inch)
4. If the clearance exceeds the service limit, measure distance (A) on the spacer collar.
Standard: 26.53 - 26.58 mm (1.044 - 1.046 inch)
Service Limit: 26.51 mm (1.044 inch)
5. If distance (A) 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.
Standard: 26.39 - 26.47 mm (1.039 - 1.042 inch)
Service Limit: 26.30 mm (1.035 inch)
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.
6. Measure the clearance between the spacer collar and 5th gear.
Standard: 0.06 - 0.24 mm (0.002 - 0.009 inch)
Service Limit: 0.3 mm (0.012 inch)
7. If the clearance exceeds the service limit, measure distance OB on the spacer collar.
Standard: 26.53 - 26.58 mm (1.044 - 1.046 inch)
Service Limit: 26.51 mm (1.044 inch)
8. If distance (B) is less than the service limit, replace the spacer collar with a new one. If distance (B) is within the service limit, measure thickness of 5th gear.
Standard: 32.89 - 32.97 mm (1 .295 - 1.298 inch)
Service Limit: 32.80 mm (1.291 inch)
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/6th synchro hub with a new one.
9. Measure the clearance between the distance collar and 6th gear.
Standard: 0.06 - 0.24 mm (0.002 - 0.009 inch)
Service Limit: 0.3 mm (0.012 inch)
10. If the clearance exceeds the service limit, measure distance & on the distance collar.
Standard: 22.03 - 22.08 mm (0.867 - 0.869 inch)
Service Limit: 22.01 mm (0.867 inch)
11. If distance g is less than the service limit, replace the distance collar with a new one. If distance & is within the service limit, measure thickness of 5th gear.
Standard: 28.39 - 28.47 mm (1.118 - 1.121 inch)
Service Limit: 28.30 mm (1.114 inch)
If the thickness of 6th gear is less than the service limit, replace 6th gear with a new one. If the thickness of 6th gear is within the service limit, replace the 5th/6th synchro hub with a new one.
Disassembly
1. Support ball bearing on steel blocks as shown, and press the shaft out of the ball bearing. Use of a jaw type puller can damage the gear teeth.
2. Support 6th gear on steel blocks as shown, and press the shaft out of the ball bearing.
3. Support 5th gear on steel blocks as shown, and press the shaft out of the 5th/6th synchro hub.
4. In the same manner as above, support the 3rd gear on steel blocks, and press the shaft out of the 3rd/4th synchro hub.
Inspection
1. Inspect the gear surface and bearing surface for wear and damage, then measure the mainshaft at points A, B, and C.
Standard:
A (Ball bearing surface): 32.002 - 32.018 mm (1.2599 - 1.2605 inch)
B (Needle bearing surface): 41.984 - 42.000 mm (1.6529 - 1.6535 inch)
C (Ball bearing surface): 30.984 - 31.000 mm (1.2198 - 1.2205 inch)
Service limit:
A: 31.950 mm (1.2579 inch)
B: 41.930 mm (1.6508 inch)
C: 30.930 mm (1.2177 inch)
If any part of the mainshaft is less than the service limit, replace the mainshaft with a new one.
2. Support the mainshaft at both ends, and inspect for runout.
Standard: 0.02 mm (0.001 inch) max.
Service Limit: 0.05 mm (0.002 inch)
If the runout exceeds the service limit, replace the mainshaft with a new one.
Reassembly
CAUTION:
- Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts.
- Press the 3rd/4th and 5th/6th synchro hubs on the mainshaft without lubrication.
- When installing the 3rd/4th and 5th/6th synchro hubs, support the shaft on steel blocks, and install the synchro hubs using a press.
- Install the 3rd/4th and 5th/6th synchro hubs with a maximum pressure of 1,000 kg (2,205 lbs), then press both the 3rd/4th and 5th/6th synchro hubs with a pressure of 2,000 kg (4,409 lbs).
- The clutch housing ball bearing is installed when it's time to check the mainshaft clearances.
1. Support 2nd gear on steel blocks, then install the 3rd/4th synchro hub using a press.
2. Install the 3rd/4th synchro sleeve by aligning the stops on the 3rd/4th synchro sleeve and hub. After installing, check the operation of the 3rd/4th synchro hub set.
3. Install the 5th/6th synchro hub using a press.
4. Install the transmission housing side ball bearing with the tapered end facing down using a press.