5. Shaft and Clutches, Disassemble & Service

Mainshaft Disassembly, Inspection, and Reassembly





1. Lubricate all parts with ATF during assembly.
2. Check the clearance of the 2nd gear.
3. Inspect the thrust needle bearing and the needle bearing for galling 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 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.

Mainshaft 2nd Gear Clearance Inspection
1. Remove the mainshaft transmission housing bearing.





2. Assemble the thrust needle bearing (A), needle bearing (B), 2nd gear (C), thrust needle bearing (D), 36.5 x 55 mm thrust washer (E), 2nd/4th clutch (F), 4th gear collar (G), thrust washer (H), snap ring (I), transmission housing mainshaft bearing (J), 1st gear collar (K), thrust washer (L), 1st clutch (M), conical spring washer (N), and locknut (O) on the mainshaft (P).





3. Tighten the locknut (A) to 29 Nm (3.0 kgf-cm, 22 ft. lbs.). The locknut has left-hand threads.





4. Hold the 2nd gear (A) against the 2nd clutch (B), then measure the clearance between the 2nd gear and 3rd gear (C) with a feeler gauge (D), in at least 3 places. Use the average as the actual clearance.
STANDARD: 0.05 - 0.13 mm (0.002 - 0.005 inch)
5. If the clearance is out of standard, remove the 36.5 x 55 mm thrust washer and measure its thickness.





6. Select and install a new thrust washer, then recheck.
7. After replacing the thrust washer, make sure the clearance is within standard.
8. Disassemble the shaft and gears.
9. Reinstall the bearing in the transmission housing.

Mainshaft Sealing Rings Replacement
The sealing rings on the mainshaft 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 the 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 ring are not twisted.
^ The chamfered ends of the ring 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 and 4th gear.
3. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
4. Inspect the splines for excessive wear and damage.
5. Check shaft bearing surfaces for scoring and excessive wear.
6. Lubricate all parts with ATF during assembly.
7. Check the clearance of the 4th gear.
8. Before installing the O-rings, wrap the shaft splines with tape to prevent O-ring damage.
9. Install the reverse selector hub, reverse selector, one-way clutch, and conical spring washer in the direction shown.

Countershaft Reverse Selector Hub Removal





Remove the reverse selector hub (A) and the 4th gear (B) with a universal 2-jaw (or 3-jaw) puller (C). Place a shaft protector (D) between the puller and countershaft (E) to prevent countershaft damage.

Countershaft Reverse Selector Hub Installation

Special Tools Required
Driver 40 mm I.D. 07746-0030100

1. Wrap the countershaft splines with tape to prevent O-ring damage.





2. Install the new O-rings (A), then remove the tape on the shaft splines.
3. Install the 3rd clutch (B), splined washer (C), thrust needle bearing (D), 3rd gear collar (E), needle bearing (F), 3rd gear (G), thrust needle bearing (H), 2nd gear (I), 28 mm distance collar (J), needle bearing (K), and 4th gear (L) on the countershaft (M).





4. Slide the reverse selector hub (A) over the countershaft (B), then press it into place with the special tool and a press.

Countershaft 4th Gear Clearance Inspection

Special Tools Required
Driver 40 mm I.D. 07746-0030100

1. Remove the countershaft transmission housing bearing.
2. Remove the O-rings from the countershaft.





3. Install the 3rd clutch (A), splined washer (B), thrust needle bearing (C), 3rd gear collar (D), needle bearing (E), 3rd gear (F), thrust needle bearing (G), 2nd gear (H), 28 mm distance collar (I), needle bearing (J), and 4th gear (K) on the countershaft (L).





4. Slide the reverse selector hub (A) over the countershaft (B), then press it into place with the special tool and a press.





5. Install the reverse gear collar (A), transmission housing bearing (B), 1st gear collar (C), needle bearing (D), 1st gear/one-way clutch/park gear (E), and conical spring washer (F) on the countershaft sub-assembly (H).
6. Tighten the locknut (G) to 29 Nm (3.0 kgf-cm, 22 ft. lbs.). The locknut has left-hand threads.








7. Measure the clearance between the 2nd gear (A) and 28 mm distance collar (B) with a feeler gauge (C) in at least 3 places. Use the average as the actual clearance.
STANDARD: 0.10 - 0.18 mm (0.004 - 0.007 inch)
8. If the clearance is out of standard, disassemble the countershaft. Remove the 28 mm distance collar, and measure its length.





9. Select and install a new distance collar, assemble the countershaft, then recheck.
10. After replacing the distance collar, make sure the clearance is within standard.
11. Disassemble the shaft and gears.
12. Reinstall the bearing in the transmission housing.

1st Gear One-way Clutch Disassembly, Inspection, and Reassembly





1. Separate countershaft 1st gear (A) from the park gear (B) by turning the park gear in the direction shown.





2. Pry the one-way clutch (A) up with tip of a screwdriver (B), and remove the one-way clutch from the countershaft 1st gear (C).





3. Inspect the park gear (A) and 1st gear (B) for wear and scoring. Inspect the one-way clutch (C) for damage and faulty movement.
4. Assemble the 1st gear, one-way clutch, and park gear.





5. Hold the 1st gear (A), and turn the park gear (B) in the direction shown to be sure it turns freely. Also make sure the park gear does not turn in the opposite direction.

Clutch Disassembly

Special Tools Required
^ Clutch spring compressor attachment 07LAE-PX40 00
^ Clutch spring compressor attachment 07HAE-PL50101
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A





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





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





3. Install the special tool on the clutch assembly.





4. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the clutches.





5. 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.





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





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





8. 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 CLUTCH





2ND/4TH CLUTCH

Clutch Reassembly

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

NOTE:
^ Clean all parts thoroughly in solvent or carburetor cleaner, and dry them with compressed air.
^ Blow out 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); if it's loose or stuck, replace the piston (B).





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





6. Install the special tools on the clutch assembly.





7. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the clutches.





8. 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.





9. Compress the return spring.





10. Install the snap ring (A).
11. Remove the special tools.





12. Install the wave spring in the 1st, 3rd, and 4th clutches.
13. Make sure the inside of the clutch drum is free of dirt and other foreign matter.





14. 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).





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





16. Set a dial indicator (A) on the clutch end plate (B).
17. Zero the dial indicator with the clutch end plate lifted up to the snap ring (c).





18. Release the clutch end plate to lower the clutch end plate, then put the special tool on the end plate (A).
19. Press the special tool down with 39 N (4 kgf, 9 lbs.) using a force gauge, and read the dial indicator (B). The dial indicator reads the clearance (C) between the clutch end plate 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: 0.65 - 0.85 mm (0.026 - 0.033 inch)
2nd Clutch: 0.65 - 0.85 mm (0.026 - 0.033 inch)
3rd Clutch: 0.4 - 0.6 mm (0.016 - 0.024 inch)
4th Clutch: 0.4 - 0.6 mm (0.016 - 0.024 inch)





20. If the clearance is not within the service limits, select a new clutch end plate from the following table.

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





CLUTCH END PLATES