Part 2 of 2

TOP GEAR SHAFT, MAIN GEAR SHAFT, AND COUNTER GEAR SHAFT (MUA)





Disassembled View

Disassembly
1. Use a pair of snap ring pliers to remove the top gear shaft snap ring (1).
2. Remove top gear shaft (2) with ball bearing (3).





3. Use a bench press and the bearing remover J-22912-01 to remove the ball bearing (3).
4. Remove needle bearing (4) and top block ring (5), mainshaft snap ring.





5. Use a pair of snap ring pliers to remove the mainshaft snap ring (6).





6. Use a bench press and the bearing remover J-22912-01 to remove the 3rd-4th synchronizer assembly (7) as a set. Disassemble the synchronizer assembly.
7. Remove 3rd block ring (8), 3rd gear (9), and needle bearing (10).
8. Remove needle bearing collar (11).





9. Use a bench press and the bearing remover J-22912-01 to remove the 1st gear (14) together with the mainshaft ball bearing (12) and 1st gear thrust bearing (13).
10. Disassemble 1st inside ring (15), 1st outside ring (16), and 1st block ring (17).
11. Remove needle bearing (18).





12. Use a pair of snap ring pliers to remove the clutch hub snap ring (19).





13. Use a bench press and the bearing remover J-22912-01 to remove the 2nd gear (24) together with 1st-2nd synchronizer assembly (20), 2nd block ring (21), 2nd outside ring (22), and 2nd inside ring (23). Disassemble the synchronizer assembly.
14. Remove needle bearing (25) from mainshaft (26).
15. Remove bearing snap ring (27)





16. Use a bench press and the bearing remover J-22912-01 to remove the front roller bearing (28).
17. Remove center roller bearing (29) from counter gear shaft (30).

Inspection And Repair
Make the necessary adjustments, repairs, and part replacements if excessive wear or damage is discovered during inspection.

Block Ring And Dog Teeth Clearance





- Use a thickness gauge to measure the clearance between the block ring and the dog teeth.
If the measured value exceeds the specified limit, the block ring must be replaced.


Block Ring And Dog Teeth Clearance
Standard: 1.5 mm (0.059 inch)
Limit: 0.8 mm (0.032 inch)

1st-2nd Synchronizer (3-Cone)





- Use a thickness gauge to measure the clearance between the block ring and the dog teeth.
If the measured value exceeds the specified limit, the 1st-2nd synchronizer assembly must be replaced.





Block Ring And Dog Teeth Clearance

Block Ring And Insert Clearance





- Use a vernier caliper or thickness gauge to measure the clearance between the block ring and the insert.
If the measured value exceeds the specified limit, the block ring and the insert must be replaced.





Block And Insert Clearance

Clutch Hub And Insert Clearance





- Use a thickness gauge to measure the clearance between the clutch hub and the insert.
If the measured value exceeds the specified limit, the clutch hub and the insert must be replaced.





Clutch Hub And Insert Clearance

Mainshaft Run-Out
- Install the mainshaft to V-blocks.





- Use a dial indicator to measure the mainshaft central portion run-out.
If the measured mainshaft run-out exceeds the specified limit, the mainshaft must be replaced.

- Mainshaft Run-out
Limit: 0.05 mm (0.0020 inch)

Gear Inside Diameter





- Use an inside dial indicator to measure the gear inside diameter.
If the measured value is less than the specified limit, the gear must be replace.





Gear Inside Diameter

Reverse Idler Gear And Idler Gear Shaft Clearance
- Use a micrometer to measure the idler gear shaft diameter.





- Use an inside dial indicator to measure the idler gear inside diameter.

- Calculate the idler gear and idler gear shaft clearance. Idler gear inside diameter-idler gear shaft diameter idle gear and idler gear shaft clearance. If the measured value exceeds the specified limit, the idle gear and/or the idler gear shaft must be replaced.

Idler Gear and Idler Gear Shaft Clearance
Standard: 0.041 - 0.074 mm (0.016 - 0.0029 inch)
Limit: 0.150 mm (0.0059 inch)


Clutch Hub Spline Play





- Set a dial indicator to the clutch hub to be measured.
- Move the clutch hub as far as possible to both the right and the left. Note the dial indicator reading. If the measured value exceeds the specified limit, the clutch hub must be replaced.





Clutch Hub Spline Play

Ball Bearing Play





- Use a dial indicator to measure the ball bearing play.
- Ball Bearing Play
Limit: 0.2 mm (0.008 inch)

Reassembly
1. Install center roller bearing (29) to counter gear shaft (30).
- Apply engine oil to the bearing inner and outer circumferences.
- Install the roller bearing in the proper direction.





NOTE: Check that outer race moves only in the direction of arrow.





2. Install front roller bearing (28) by performing the following steps.
- Use bearing installer to install the front roller bearing inner race to the counter gear shaft.
- Install the outer race and roller assembly. The snap ring groove must be facing the transmission front side.
- Use bearing installer J-35283 to install the ring.
3. Install bearing snap ring (27) to mainshaft (26).
4. Apply engine oil to the needle bearing (25) and the 2nd gear thrust surfaces. Install the needle bearing (25) and the 2nd gear (24) to the mainshaft.





The 2nd gear dog teeth must be facing the transmission rear side.





5. Assemble 2nd inside ring (23), 2nd outside ring (22), and 2nd block ring (21).
- Apply engine oil to the synchronizer ring friction surfaces.
6. Assemble 1st-2nd synchronizer assembly by performing the following steps:








1. Check that the inserts (3) fit snugly into the block ring insert grooves.
2. Check that the inserts springs (4) are fined to the inserts as shown in the illustration.
3. Check that the clutch hub (5) and the sleeve (6) slide smoothly.
4. Install the synchronizer assembly to the mainshaft. The clutch hub face (with the heavy boss) must be facing the 2nd gear side.

7. Install clutch hub snap ring (19) by performing the following steps:





- Select the snap ring which will provide the minimum clearance between the 1st-2nd clutch hub and the snap ring.
There are three snap ring sizes available.





The snap rings are color coded to indicate their thickness.

- Clutch Hub and Snap Ring Clearance
Standard: 0 - 0.1 mm (0 - 0.004 inch)





Snap Ring Availability





- Use a pair of snap ring pliers to install the snap ring to the mainshaft. The snap ring must be fully inserted into the mainshaft snap ring groove.





8. Install needle bearing (18), 1st block ring (17), 1st outside ring (16), 1st inside ring (15), and 1st gear (14).
- Apply engine oil to the needle bearing, 1st gear thrust surfaces and synchronizer ring friction surfaces.
- Install the needle bearing and the 1st gear to the mainshaft. The 1st gear dog teeth must be facing the transmission front side.





9. Install the 1st gear thrust bearing and the race (13) to the main shaft. The thrust bearing side must be facing the transmission front side.





10. Apply engine oil to the mainshaft ball bearing (12) and the mainshaft (26). Install the ball bearing (12) and needle bearing collar (11) to the mainshaft (26). The ball bearing snap ring groove must be facing the transmission rear side. Use a bench press and installer J-6133-01 to slowly force the collar into place.





11. Apply engine oil to the needle bearing and the 3rd gear thrust surfaces. Install the needle bearing (10) and the 3rd gear (9) to the mainshaft. The 3rd gear dog teeth must be facing the transmission front side.
12. Install 3rd block ring (8).








13. Check and install 3rd-4th synchronizer assembly (7) by the following steps:
1. Check that the inserts (3) fit snugly into the block ring insert grooves.
2. Check that the insert springs (4) are fitted to the inserts as shown in the illustration.
3. Check that the clutch hub (5) and the sleeve (6) slide smoothly.
4. Install the synchronizer assembly to the mainshaft. The clutch hub face (with the heavy boss) must be facing the 3rd gear side.
14. Select and install mainshaft snap ring (6) in the following way:





- Select the snap ring which will provide the minimum clearance between the 3rd-4th clutch hub and the snap ring.





There are three snap ring sizes available. The snap rings are color coded to indicate their thickness.

- Clutch Hub And Snap Ring Clearance
Standard: 0 - 0.1 mm (0 - 0.004 inch)





Snap Ring Availability

- Use a pair of snap ring pliers to install the snap ring to the mainshaft. The snap ring must be fully inserted into the mainshaft snap ring groove.

15. Install top block ring (5).
16. Apply grease to the bearing inner and outer circumferences and install needle bearing (4).





17. Use a bench press to install the top gear shaft ball bearing (3) to the top gear shaft (2). The snap ring groove must be facing the transmission front side.
18. Use a pair of snap ring pliers to install the top gear shaft snap ring (1) to the bearing.