Disassembly and Assembly

DISASSEMBLY




1. Before disassembly, check 5th input gear end play.

Gear end play:
0.18 - 0.31 mm (0.0011 - 0.0122 in)

- If not within specification, disassemble and check contact surface of gear, shaft and hub. Then check clearance of snap ring groove - Refer to Assembly below.




2. Remove snap ring and 5th stopper.




3. Remove 5th synchronizer, 5th input gear and 5th gear needle bearing with tool.




4. Remove snap ring of input shaft front bearing and input gear spacer.




5. Pull out input shaft front bearing.
6. Remove bearing retainer.

ASSEMBLY




1. Assemble 5th synchronizer.




Note: Be careful not to hook front and rear ends of spread spring to the same insert.




2. Install bearing retainer.
3. Press on input shaft front bearing with tool.
4. Install input gear spacer.

Snap Rings Of Input Shaft Front Bearing:

5. Select proper snap ring of input shaft front bearing to minimize clearance of groove in input shaft and install it.

Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)




- Be sure to replace 5th gear synchronizer hub with new one when it is removed.
6. Install 5th gear needle bearing, 5th input gear, 5th synchronizer and 5th stopper.
- Be sure to press input shaft in position vertically in relation to synchronizer hub.
7. Measure gear end play as a final check - Refer to Disassembly above.




8. Select proper snap ring of 5th synchronizer hub to minimize clearance of groove in input shaft and install it.

Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Snap ring of 5th synchronizer: [1][2]Mechanical Specifications