Part 2
COUNTERSHAFT ASSEMBLYIndex
NOTE: The 3rd, 4th, 5th and 6th gears 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, 5th and 6th gears should be installed without lubrication using a press.
Clearance Inspection
1. Measure the clearance between 2nd and 3rd gear.
Standard: 0.04 - 0.10 mm (0.002 - 0.004 inch)
2. If the clearance exceeds the standard, select the appropriate spacer collar for the correct clearance from the chart below.
3. Measure the clearance between 1st and reverse gear.
Standard: 0.04 - 0.10 mm (0.002 - 0.004 inch)
4. If the clearance exceeds the standard, select the appropriate thrust washer for the correct clearance from the chart below.
Disassembly
NOTE: Remove the gears using a press and steel blocks. Use of a jaw-type puller can damage the gear teeth.
1. Securely clamp the countershaft assembly in a bench vise with wood blocks.
2. Raise the locknut tab from the groove of the countershaft, and remove the locknut and the spring washer.
NOTE: The locknut has left-hand threads.
3. Support 6th gear on steel blocks, and press the shaft out of ball bearing, needle bearing, and 6th gear.
4. Support 4th gear on steel blocks, and press the shaft out of 5th and 4th gears.
5. Support 2nd gear on steel blocks, and press the shaft out of 3rd and 2nd gears.
Inspection
1. Inspect the gear surfaces and bearing surfaces for wear and damage, then measure the countershaft at points A and B inspect oil passages for clogging.
Standard: A (Needle bearing surface): 43.974 - 43.990 mm (1.7313 - 1.7319 inch)
B (Ball bearing surface): 33.984 - 34.000 mm (1.3380 - 1.3386 inch)
Service limit:
A: 43.920 mm (1.7291 inch)
B: 33.930 mm (1.3358 inch)
If any part of the countershaft is less than the service limit, replace it with a new one.
2. Support the countershaft 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 countershaft 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, 5th and 6th gears on the counter shaft without lubrication.
- When installing the 3rd, 4th, 5th and 6th gears, support the shaft on steel blocks, and install the gears using a press.
- Install the 3rd, 4th, 5th and 6th gears with a maximum pressure of 1,000 kg (2,205 lbs), then press all three gears with a pressure of 2,600 kg (5,732 lbs).
1. Support the countershaft on a steel block, and install 3rd gear using a press.
2. Install 4th gear using a press.
3. Install 5th gear using a press.
4. Install 6th gear using a press.
5. Install the needle bearing using a press then install the bearing outer race.
6. Install the ball bearing using a press.
7. Securely clamp the countershaft assembly in a bench vise with wood blocks.
8. Install the spring washer, tighten the locknut, then stake the locknut tab into the groove.
NOTE: The locknut has left-hand threads.
LOCKNUT
113 -> 0 -> 113 Nm
(11.5 -> 0 -> 11.5 kgf-m, 83 -> 0 -> 83 ft. lbs.)
SYNCHRO SLEEVE, SYNCHRO HUB
Inspection
1. Inspect gear teeth on all synchro hubs and synchro sleeves for rounded off corners, which indicates wear.
2. Install each synchro hub in its mating synchro sleeve, and check for freedom of movement. If replacement is required, always replace the synchro sleeve and synchro hub as a set.
Installation
Each synchro sleeve has three sets of longer teeth (120° apart) that must be matched with the three sets of deeper grooves in the synchro hub when assembled. Installing the synchro sleeve with its longer teeth in the synchro hub slots will damage the spring ring.
SYNCHRO RING, GEAR
Inspection
1. Inspection the synchro ring and gear.
A:Inspect the inside of the synchro ring for wear.
B:Inspect the synchro sleeve teeth and matching teeth on the synchro ring for wear (rounded off).
C:Inspect the synchro sleeve teeth and matching teeth on the gear for wear (rounded off).
D:Inspect the gear hub thrust surface for wear.
E:Inspect the cone surface for wear and roughness.
F:Inspect the teeth on all gears for uneven wear, scoring, galling, and cracks.
2. Coat the cone surface of the gear with oil, and place the synchro ring on the matching gear. Rotate the synchro ring, making sure that it does not slip.
Measure the clearance between the synchro ring and gear all the way around. Hold the synchro ring against the gear evenly while measuring the clearance.
Synchro Ring-to-Gear Clearance
Standard: 0.85 - 1.1 mm (0.033 - 0.043 inch)
Service Limit: 0.4 mm (0.016 inch)
Double Cone Synchro-to-Gear Clearance Standard:
(A):(Outer Synchro Ring to Synchro Cone) 0.5 - 1.0 mm (0.020 - 0.039 inch)
(B):(Synchro Cone to Gear) 0.5 - 1.0 mm (0.020 - 0.039 inch)
(C):(Outer Synchro Ring to Gear) 0.95 - 1.68 mm (0.037 - 0.066 inch)
Service Limit:
(A): 0.3 mm (0.012 inch)
(B): 0.3 mm (0.012 inch)
(C): 0.6 mm (0.024 inch)
If the clearance is less than the service limit, replace the synchro ring and synchro cone.
OIL PUMP
Disassembly/Reassembly
Oil Pump Part 1 Of 2:
Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces.
Clearance Inspection
1. Check the clearance between the transmission mating surface of the clutch housing and the oil pump gear.
Standard: 0.3 - 0.8 mm (0.012 - 0.031 inch)
Service Limit: 0.9 mm (0.035 inch)
2. Check the axial clearance on the pump rotor.
Clutch Housing-to-Rotor Axial clearance
Standard: 0.03 - 0.1 mm (0.001 - 0.004 inch)
Service Limit: 0.15 mm (0.006 inch)
3. Check the radial clearance on the pump rotor.
Inner Rotor-to-Outer Rotor Radial clearance
Standard: 0.14 mm (0.006 inch) max.
Service Limit: 0.2 mm (0.008 inch)
4. Check the radial clearance between the clutch housing and the outer rotor.
Clutch Housing-to-Rotor Radial clearance
Standard: 0.1 - 0.2 mm (0.004 - 0.008 inch)
Service Limit: 0.22 mm (0.009 inch)
MAINSHAFT OIL SEAL (CLUTCH HOUSING)
Replacement
1. Remove the release bearing guide cover, and release bearing guide.
2. Remove the oil seal.
3. Drive a new oil seal from the clutch side using the special tools as shown.
4. Install the release bearing guide, and release bearing guide cover.
COUNTERSHAFT BEARING (CLUTCH HOUSING)
Replacement
1. Remove the bearing retaining plate.
2. Remove the needle bearing with the special tool, then remove the oil guide plate.
3. Position the oil guide plate and new needle bearing in the bore of the clutch housing. Position the needle bearing with the oil hole facing up.
4. Drive the needle bearing using the special tools.
5. Install the bearing retaining plate, and stake the bolt heads in the groove in the bearing retaining plate.
MAINSHAFT THRUST SHIM
Adjustment
1. Remove the thrust shim and oil guide plate from the transmission housing.
2. Install the mainshaft in the transmission housing.
Do not install the clutch housing side ball bearing.
3. Measure distance * between the end of the transmission housing and mainshaft. Use a straight edge and feeler gauge, and measure at three locations and average the readings.
4. Set the mainshaft ball bearing in the clutch housing, and measure distance (B) or (C) between the surfaces of the clutch housing and the bearing inner race. Use a straight edge and feeler gauge, and measure at three locations and average the readings. Do not install the spring washer.
5. Select the proper thrust shim on the basis of the following calculations. Do not use more than two thrust shims.
(Basic Formula)
A + B - 0.99 mm = shim thickness (max.)
A + B - 1.06 mm = shim thickness (min.)
A - C - 0.99 mm = shim thickness (max.)
A - C - 1.06 mm = shim thickness (min.)
NOTE: Clean all the parts thoroughly before installation.
6. Install the oil guide plate and thrust shim into the transmission housing.
7. Install the ball bearing onto the mainshaft using the special tools.
8. Install the 75 mm spring washer and mainshaft assembly into the clutch housing.
9. Install the transmission housing.
Torque: 44 Nm (4.5 kgf-m, 33 ft. lbs.)
10. Check the thrust clearance in the manner described below. Carry out the measurement at normal room temperature.
a. Slide the mainshaft base over the mainshaft.
b. Attach the mainshaft holder to the mainshaft as follows:
- Back-out the mainshaft holder bolt and loosen the two hex bolts.
- Fit the holder over the mainshaft so its lip is towards the transmission.
- Align the mainshaft holder's lip around the groove at the inside of the mainshaft splines, then tighten the hex bolts.
c. Seat the mainshaft full by tapping its end with a plastic hammer.
d. Thread the mainshaft holder bolt in until it just contacts the wide surface of the mainshaft base.
e. Zero a dial gauge on the end of the mainshaft.
f. Turn the mainshaft holder bolt clockwise; stop turning when the dial gauge has reached its maximum movement. The reading on the dial gauge is the amount of mainshaft end play.
CAUTION: Turning the shaft holder bolt more then 60 degrees after the needle of the dial gauge stops moving may damage the transmission.
g. If the reading is within the standard, the clearance is correct.
If the reading is not within the standard, recheck the shim thickness.
Standard: 0.14 - 0.21 mm (0.006 - 0.008 inch)