5. Shafts and Clutches Disassemble & Service

Mainshaft Disassembly, Inspection, and Reassembly

1. Lubricate all parts with ATF during assembly.
2. Check the clearance of the 4th/5th clutch assembly.
3. Inspect the thrust needle bearing and the needle bearing for scoring and rough movement.
4. Inspect the splines for excessive wear and damage.
5. Check shaft bearing surfaces for scoring and excessive wear.
6. Before installing the O-rings, wrap the shaft splines with tape to prevent O-ring damage.
7. Install the 41 x 73 mm thrust shim and conical spring washer in the direction shown.
8. Inspect the condition of the sealing rings. If the sealing rings are worn, distorted, or damaged, replace them.

4th/5th Clutch Clearance Inspection
1. Remove the O-rings from the mainshaft.

2. Assemble the 41 x 73 mm thrust shim (A), 4th/5th clutch assembly (B), and 5th gear collar (C) on the mainshaft (D).

3. Hold the 5th gear collar (C) against the clutch assembly (B), then measure the clearance between the clutch guide (E) and the 5th gear collar with a feeler gauge (F) in at least three places. Use the average as the actual clearance.
4. If the clearance is out of standard, remove the thrust shim and measure its thickness.

5. Select and install a new shim, then recheck.
6. After replacing the thrust shim, make sure the clearance is within standard.

Mainshaft Sealing Ring Replacement
The sealing rings are synthetic resin with chamfered ends. Check the condition of the sealing rings, and replace them only if they are worn, distorted, or damaged.

1. For a better fit, squeeze sealing rings together slightly before installing them.

2. Apply ATF to the new sealing rings then install them on the mainshaft.
3. After installing the sealing rings, verify the following:
- The rings are fully seated in the groove.
- The rings are not twisted.
- The chamfered ends of the rings are properly joined.

Countershaft Disassembly, Inspection, and Reassembly

1. Remove the locknut, and take off components down to the reverse selector hub.
2. Remove the reverse selector hub, 4th gear, and 1st gear.
3. Check the bearing on the 3rd clutch for wear and rough movement. If the bearing is worn or damaged, replace it.
4. Inspect the thrust needle bearing and the needle bearing for scoring and rough movement.
5. Check the splines for excessive wear and damage.
6. Check the shaft bearing surfaces for scoring and excessive wear.
7. Lubricate all parts with ATF, and reassemble the shaft and gears.
8. Install the distance collars, reverse selector hub, reverse selector, splined washer, and conical spring washer in the direction shown.

Countershaft Reverse Selector Hub and 4th Gear Removal

1. Remove the reverse selector hub (A) and the 5th gear (B) from the countershaft with a press. Place a shaft protector (C) between the countershaft and press to prevent damaging the countershaft.

NOTE: Some reverse selector hubs are not press-fitted, and can be removed without using a press.

2. Remove the needle bearing, snap ring, 35 x 47 x 7.8 mm distance collar, 31 mm cotters, 35 x 47 x 45.6 mm distance collar, and 31 mm cotters from the countershaft.

3. Remove the 1st gear (A) and 4th gear (B) from the countershaft with a press. Place a shaft protector (C) between the countershaft and press to prevent damaging the countershaft.

Countershaft 4th Gear and Reverse Selector Hub Installation
Special Tools Required
- Driver, 40 mm I.D. 7746-0030100

1. Apply ATF to these parts.
2. Install the 1st gear on the countershaft by hand.

3. Align the shaft splines with those on 4th gear, then press the countershaft (A) into the 4th gear with a press. Place a shaft protector (B) between the countershaft and press to prevent damaging the countershaft.
4. Stop pressing the countershaft when the 4th gear contacts the 1st gear (C).

5. Install the 31 mm cotters, 35 x 47 x 45.6 mm distance collar, 31 mm cotters, 35 x 47 x 7.8 mm distance collar, snap ring, needle bearing, and 5th gear (A) on the countershaft.
6. Slide the reverse selector hub (B) over the countershaft (C), then press it into place with the special tool and a press.

NOTE: Some reverse selector hubs are not press fitted, and can be installed without using the special tool and a press.

3rd Clutch Ball Bearing Replacement
Special Tools Required
- Driver 07749-00 10000
- Attachment, 62 x 68 mm 07746-0010500

NOTE: Check the bearing for wear and rough movement. If the bearing is OK, removal is not necessary.

1. Remove the ball bearing (A) from the 3rd clutch with a commercially available bearing puller (B), bearing separator (C), and stepped adapter (D).

2. Install the new bearing on the 3rd clutch with the special tools and a press.

Secondary Shaft Disassembly, Inspection, and Reassembly

1. Remove the locknut and disassemble the shaft and gears.
2. Inspect the thrust needle bearing and needle bearing for scoring and rough movement.
3. Check the clearance of the secondary shaft assembly.
4. Check the splines for excessive wear and damage.
5. Check the shaft bearing surfaces for scoring and excessive wear.
6. Check the idler gear bearing for wear and rough movement. If the bearing is worn or damaged, replace it.
7. Before installing the O-rings, wrap the shaft splines with tape to prevent damage to the O-rings.
8. Lubricate all parts with ATF during reassembly.
9. Install the conical spring washer and splined washer in the direction shown.

Secondary Shaft Clearance Inspection
1. Remove the O-rings from the secondary shaft.

2. Assemble the thrust needle bearing (A), 1st gear assembly (B), needle bearings (C), thrust needle bearing (D), 38 x 56.5 mm splined washer (E), 32 mm cotters (F), cotter retainer (G), and snap ring (H) on the secondary shaft (I).

3. Measure the clearance between the 38 x 56.5 mm splined washer (E) and cotters (F) with a feeler gauge (J) in at least three places. Use the average as the actual clearance.
4. If the measurement is out of standard, remove the splined washer, and measure its thickness.

5. Select and install a new splined washer, then recheck the clearance.
6. Remove the 27 x 47 x 5 mm thrust washer from the mainshaft.

7. Assemble the 1st/1st-hold/2nd clutch assembly (A), 37 x 55 mm thrust washer (B), thrust needle bearing (C), needle bearings (D), 2nd gear (E), thrust needle bearing (F), and 27 x 47 x 5 mm thrust washer (removed from mainshaft) (G) on the secondary shaft subassembly (H).

8. Set the dial indicator (I) on the 2nd gear (E).

9. Hold the 27 x 47 x 5 mm thrust washer (G) against the clutch assembly (A), and measure the 2nd gear axial clearance in at least three places while moving the 2nd gear (E). Use the average as the actual clearance.
10. If the measurement is out of standard, remove the 37 x 55 mm thrust washer and measure its thickness.

11. Select and install a new thrust washer, then recheck the clearance.
12. Disassemble the shaft and gears.
13. Reinstall the 27 x 47 x 5 mm thrust washer on the mainshaft.

Secondary Shaft Idler Gear Bearing Replacement
Special Tools Required
- Driver 07749-0010000
- Attachment, 78 x 90 mm 07GAD-SD40101

1. Check the bearing for wear, damage, and rough movement. If the bearing is worn or damaged, go to step 2.
2. Place the secondary shaft idler gear in a vise with soft jaws.

3. Remove the bearing (A) from the secondary shaft idler gear (B) with a commercially available bearing puller (C).

4. Install the bearing on the secondary shaft idler gear with the special tools and a press.

1st Gear One-way Clutch Inspection

1. Hold the 1st-hold clutch hub (A), and turn the 1st gear (B) in the direction shown to be sure it turns freely. Also make sure the 1st gear does not turn in the opposite direction.
2. If any problem occurs on the 1st gear one-way clutch, replace the 1st clutch hub (C). The 1st gear one-way clutch is not available separately from the 1st clutch hub.

1st Clutch Hub Replacement
Special Tools Required
- Driver 07749-0010000
- Driver attachment 07947-6340500
- Attachment, 78 x 90 mm 07GAD-SD40101

1. Remove the 1st-hold clutch hub (A) from the 1st gear (B) with the special tools and a press.
2. Remove the 1st clutch hub (C) from the 1st gear, then install the new 1st clutch hub in the 1st gear.

3. Install the 1st-hold clutch hub (A) in the 1st gear (B) with the special tools and a press.

Clutch Disassembly
Special Tools Required
- Clutch spring compressor attachment 07 LAE-PX40100 or 07HAE-PL50101
- Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A

1. Remove the snap ring (A) with a screwdriver (B), then remove the clutch end-plate, the clutch discs, and the plates with a screwdriver.

2. Remove the disc spring from the 1st, 3rd, 4th, and 5th clutches.

3. Install the special tools on the clutch assembly.

4. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 1st, 4th, and 5th clutches.

5. Set the special tool (A) on the spring retainer (B) of the 2nd and 3rd clutches in such a way that the special tool works on the clutch return spring (C).

6. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.

7. Compress the spring until the snap ring can be removed.

8. Remove the snap ring (A). Then remove the special tools (B), spring retainer (C), return spring.

9. Wrap a shop rag around the clutch drum (A), and apply air pressure to the fluid passage to remove the piston (B). Place a finger tip on the other end while applying air pressure.

Clutch Inspection
1st/1st-hold/2nd Clutch

1. Inspect the clutch piston and clutch piston check valve. If the clutch check valve is loose or stuck damaged, replace the clutch piston.
2. Check the spring retainer for wear and damage.
3. Inspect the clutch discs, clutch plates, and clutch end-plate for wear, damage, and discoloration.
- If the clutch discs are worn or damaged, replace the discs as a set.
- If the clutch plates are worn, damaged, or discolored, replace the plates as a set.
- If the clutch end-plate is worn, damaged, or discolored, inspect the clutch end-plate-to-top-disc clearance, then replace the clutch end-plate.

Clutch Reassembly
Special Tools Required
- Clutch spring compressor attachment 07LAE-PX40100 or 0714AE-PL50101
- Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A
- Clutch compressor attachment 07ZAE-PRP0100

Note these items during reassembly:
- Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air.
- Blowout all passages.
- Apply ATF to all parts before assembly.

1. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.

2. Inspect the check valve (A) on the clutch pistons (B). If the check valve is loose or stuck, replace the piston.

3. Install new O-rings (A) on the piston (B).

4. Install the piston (A) in the clutch drum (B). Apply pressure and rotate to ensure proper seating. Lubricate the piston O-ring with ATF before installing. Do not pinch the O-ring by installing the piston with too much force.
5. Check the 1st-hold, clutch end-plate-to-top-disc clearance; starting with a clutch plate, alternately install the clutch plate and discs in the 1st-hold clutch drum, then install the 1st-hold clutch plate B.

6. Measure the 1st-hold clutch clearance between the 1st-hold clutch plate B and the top disc (A) with a feeler gauge (C) while pressing the 1st-hold clutch plate B down. Take measurements in at least three places, and use the average as the actual clearance.
7. If the clearance is out of standard, replace the 1st hold clutch plates and discs as a set, and recheck.

8. Install the return spring (A) and spring retainer (B), and position the snap ring (C) on the retainer.

9. Install the special tools on the clutch assembly.

10. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 1st, 4th, and 5th clutches.

11. Set the special tool (A) on the spring retainer (B) of the 2nd and 3rd clutches so the tool works on the clutch return spring (C).

12. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.

13. Compress the return spring.

14. Install the snap ring (A).
15. Remove the special tools.

16. Install the disc spring in the 1st, 3rd, 4th, and 5th clutches in the direction shown.
17. Make sure the inside of the clutch drum is free of dirt and other foreign particles.

18. Starting with a clutch plate, alternately install the clutch plates and discs. Install the clutch end-plate (A) with the flat side toward the disc (B).

19. Install the snap ring (A) with a screwdriver (B).

20. Set a dial indicator (A) on the clutch end-plate (B).
21. Zero the indicator with the clutch end-plate lifted up to the snap ring (C).

22. Release the clutch end-plate to lower it, then put the special tool on the end plate (A)
23. Press the special tool down with 39 N (4 kgf, 9 lbs) using a force gauge, and use a the dial indicator (B) to read the clearance (C) between the clutch endplate and top disc (D). Take measurements in at least three places, and use the average as the actual clearance.
Clutch End-Plate-to-Top-Disc Clearance Service Limit
1st Clutch: 1.1 - 1.3 mm (0.043 - 0.061 inch)
2nd Clutch: 0.85 - 1.05 mm (0.033 - 0.041 inch)
3rd Clutch: 0.7 - 0.9 mm (0.028 - 0.035 inch)
4th Clutch: 0.55 - 0.75 mm (0.022 - 0.0 inch)
5th Clutch: 0.55 - 0.75 mm (0.022 - 0.030 inch)

24. If the clearance is out of service limit, select a new clutch end-plate from the table. Install the new clutch end-plate, then recheck the clearance.

NOTE: If the thickest clutch end-plate is installed, but the clearance is still over the service limit, replace the clutch discs and plates.