Part 1 of 2
REASSEMBLY1. Install the top gear shaft assembly.
1. Using installer J-42904 and a press, install anew bearing.
NOTE: Outer race snap ring groove (1) toward front.
2. Select a snap ring that will allow minimum axial play.
3. Using a snap ring expander, install the new snap ring.
4. Install the 4th block ring.
5. Using a thickness gauge, measure the clearance between the synchronizer ring back and gear spline end.
Standard: 0.75 - 1.65 Nm (0.030 - 0.065 inch)
6. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks. If it does not lock, replace the synchronizer ring.
7. Install the needle roller bearing.
2. Reassemble the main shaft assembly.
NOTE: Apply all parts with gear oil before installing them.
3. Inspect block ring
1. Using a thickness gauge, measure the clearance between the synchronizer ring back and gear spline end.
2. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
4. Inspect hub sleeve and shift arm.
1st-2nd shift arm
1. Using a vernier caliper, measure center groove of the 1st-2nd shift arm.
Reference: 5.28 mm (0.208 inch)
2. Using a vernier caliper, measure flange of the reverse gear. Calculate the clearance between the reverse gear and shift arm.
Reference: Reverse gear flange thickness 5.0 mm (0.197 inch)
Standard: 0.15 - 0.41 mm (0.006 - 0.016 inch)
3rd-4th shift arm
1. Using a vernier caliper, measure tip of the shift arm thickness.
Reference: 110.0 mm (0.39 inch)
2. Using a vernier caliper, measure center groove of the hub sleeve. Calculate the clearance between the hub sleeve No.2 and shift arm.
Reference: Center groove dimension 10.2 mm (0.402 inch)
Standard: 0.15 - 0.35 mm (0.006 - 0.014 inch)
5. Inspect clutch hub and hub sleeve.
1. Check for wear or damage.
2. Install the hub sleeve to the clutch hub, and check sliding smoothly.
6. Inspect gear inside diameter.
1. Using a inside dial indicator, measure the gear inside diameter.
7. Inspect mainshaft.
1. Using a micrometer, measure the outer diameter of the mainshaft journal.
2. Using a micrometer, measure the mainshaft flange thickness.
Standard: 5.0 Nm (0.197 inch)
3. Install the mainshaft to V-blocks.
4. Use a dial indicator to measure the mainshaft central portion run-out.
Standard: less than 0.015 mm (0.0006 inch)
8. Install 3rd gear.
1. Install the 3rd gear needle bearing, and 3rd block ring to the mainshaft.
9. Install the clutch hub No. 2.
1. Install the clutch hub No. 2 and hub sleeve No.2.
NOTE: Be careful the direction of the clutch hub No. 2, as shown.
2. Using a screwdriver, install 3 inserts and springs.
NOTE: Position the key springs so that their end gaps are not in line.
3. Using installer J-42797 and a press, install the hub sleeve No.2.
NOTE:
^ Align the synchronizer ring key.
^ Check that the gear rotates smoothly.
4. Select a snap ring that will allow minimum axial play.
5. Using a snap ring expander, install the new snap ring.
NOTE: Be careful not to damage the bearing surface.
6. Using a thickness gauge, inspect the 3rd gear thrust clearance.
Standard: 0.10 - 0.25mm (0.004 - 0.010 inch)
10. Install the 2nd gear.
1. Check the install direction.
NOTE: Align the nail of middle ring with gear spline slots.
2. Install the needle roller bearing 2nd gear and 2nd gear block ring set to the mainshaft.
11. Install the clutch hub No. 1.
1. Install the 3 inserts and 3 insert springs to the clutch hub No. 1.
Reference: While pushing the insert spring with a screwdriver, install the inserts.
2. Install the clutch hub No.1 to the reverse gear.
NOTE: Check the clutch hub No. 1 installing direction, as shown.
3. Using installer J-42798 and a press, install the hub No.1 by retaining the reverse gear.
NOTE:
^ Align the projection of inner ring with hub No. 1 slots.
^ Check that the gear rotates smoothly.
4. Select a snap ring that will allow minimum axial play.
5. Using a screwdriver and hammer, install the snap ring.
NOTE: Be careful not to damage the bearing surface.
6. Check that the gear rotates smoothly.
7. Using a dial indicator, measure the 2nd gear thrust clearance.
Standard: 0.10 - 0.25mm (0.004 - 0.010 inch)
12. Install the 1st gear.
1. Install the following parts:
1. 1st gear bearing spacer (4).
2. 1st gear needle roller bearing (3).
3. Synchronizer ASM (2).
4. 1st gear(l).
NOTE:
^ Align the projection of inner ring with hub No.1 slots.
^ Check that the gear rotates smoothly.
2. Install the 1st gear thrust washer pin and 1st gear thrust washer to the mainshaft.
NOTE: Align the straight pin with the thrust washer.
13. Install the main shaft center bearing.
1. Using installer J-42799 and a press, install the main shaft center bearing.
NOTE: Center bearing snap ring groove toward rear.
2. Using a thickness gauge, measure 1st gear thrust clearance.
Standard: 0.10 - 0.45mm (0.004 - 0.018 inch)
14. Install the 5th gear.
1. Using installer J-42799 and a press, install the 5th gear.
2. Select a snap ring that will allow minimum axial play.
3. Using a screwdriver and hammer, install the new snap ring.
15. Inspect each gear radial clearance.
1. Mount the main shaft through the aluminum plate in a vise.
2. Using a dial indicator, measure the radial clearance of each gear.
16. Install the counter gear shaft.
1. Check the counter front bearing inner race and the side race, as shown.
2. Using installer J-42800 and a press, install the counter gear shaft front bearing.
3. Select a snap ring that will allow minimum axial play.
4. Using a snap ring expander, install the new snap ring.
17. Install the front cover.
1. Using installer J-42801, grip J-8092 and a hammer drive in a new oil seal.
Drive in depth (from cover end): 11.7 ± 0.5 mm (0.46 ± 0.02 inch)
2. Apply grease to the seal lip.
18. Install the transfer adapter.
1. Using installer J-42802, and a hammer drive in a new oil seal.
Drive in depth (from transfer adapter): 10.95 ± 0.5 mm (0.431 ± 0.02 inch)
2. Apply grease to the oil seal lip.
3. Install the oil receiver pipe.
4. Install the reverse restrict to the transfer adapter.
5. Using a pin punch and hammer, drive in the slotted spring pin.
6. Clean up the plug and plug hole.
7. Apply sealant to the plug threads. (THREE BOND 1344 or equivalent)
8. Using a torx socket wrench (T40), install and torque the plug.
Torque: 18.5 Nm (13.5 ft. lbs.)
9. Using hexagon wrench install and torque the plug.
Torque: 37 Nm (27 ft. lbs.)
19. Install the reverse shift arm No. 1 and reverse shift arm No. 2.
1. Mount the intermediate plate through the aluminum plate in a vise.
2. Using 2 bolts, install reverse shift arm bracket.
Torque: 18 Nm (13 ft. lbs.)
3. Install reverse shift arm No. 2 to the reverse shift arm No.1. Using screwdriver and a hammer, install the new E-ring.
4. Install reverse shift arm No. 2 to the reverse shift arm bracket.
20. Install the reverse shift rod.
1. Install the reverse shift arm No.1 compression spring and ball to the reverse shift arm No. 1.
2. Install the reverse shift rod from the rear side by pushing the ball on using a screwdriver.