Part 1
CASE COMPONENTS
GEAR COMPONENTS
SHIFT CONTROL COMPONENTS
DISASSEMBLY
CASE COMPONENTS
1. Remove rear extension.
a. Remove control housing, check ball, return spring plug, select check plunger and return springs.
b. Drive out striking arm retaining pin.
c. Remove striking arm from striking rod.
d. Remove rear extension by lightly tapping it.
2. Remove front cover, gasket, shim of countershaft front bearing, and snap ring of main drive gear ball bearing.
3. Remove transmission case by tapping lightly.
4. Remove front cover oil seal.
- Be careful not to damage front cover mating surface.
SHIFT CONTROL COMPONENTS
1. Set up Tool on adapter plate.
2. Remove striking rod from adapter plate.
3. Remove check ball plugs, check springs, and check balls.
4. Drive out retaining pins. Then drive out fork rods and remove interlock balls.
5. Draw out 3rd-4th and OD-reverse fork rods.
GEAR COMPONENTS
1. Before removing gears and shafts, measure each gear end play.
Gear end play: Refer to image.
If not within specification, disassemble and check contact surface of gear to hub, washer, bushing, needle bearing and shaft.
2. Mesh 2nd and reverse gear, then draw out counter front bearing with suitable puller.
3. Remove snap ring and then remove sub-gear bracket, subgear spring and sub-gear.
4. Draw out counter drive gear with main drive gear assembly with suitable puller.
- When drawing out main drive gear assembly, be careful not to drop pilot bearing and baulk ring.
5. Remove rear side components on mainshaft and counter gear.
a. Release staking on countershaft nut and mainshaft nut loosen these nuts.
- Mainshaft lock nut: Left-hand thread
b. Pull out OD counter gear with bearing with suitable puller.
c. Draw out reverse counter gear and spacer.
d. Remove snap rings from reverse idler shaft and draw out reverse idler gear, thrust washers and reverse idler gear bearing.
e. Remove speedometer drive gear and steel ball.
f. Remove snap ring and pull out OD mainshaft bearing, then remove snap ring.
g. Remove mainshaft nut.
h. Remove steel roller and washer.
i. Remove roller bearing and washer.
j. Remove OD main gear, needle bearing and baulk ring (OD).
k. Remove OD coupling sleeve and shifting inserts.
l. Press out mainshaft and counter gear alternately.
- Press down mainshaft and counter gear alternately and carefully. Do not allow gears attached to mainshaft and counter gear underneath adapter plate to hit each other.
6. Remove front side components on mainshaft.
a. Remove 1st gear washer and steel ball.
b. Remove 1st main gear and 1st gear needle bearing.
- Be careful not to lose steel ball.
c. Press out 2nd main gear together with 1st gear bushing and 1st & 2nd synchronizer assembly.
d. Remove mainshaft front snap ring.
e. Press out 3rd main gear together with 3rd & 4th synchronizer assembly and 3rd gear needle bearing.
7. Remove main drive gear bearing.
a. Remove main drive gear snap ring and spacer.
b. Press out main drive gear bearing.
INSPECTION
SHIFT CONTROL COMPONENTS
- Check contact surface and sliding surface for wear, scratches, projections or other damage.
GEAR COMPONENTS
GEAR AND SHAFT
- Check shafts for cracks, wear or bending.
- Check gears for excessive wear, chips or cracks.
SYNCHRONIZERS
- Check spline portion of coupling sleeves, hubs and gears for wear or cracks.
- Check baulk rings for cracks or deformation.
- Check shifting inserts for wear or deformation.
- Check spread spring for deformation.
- Measure clearance between baulk ring and gear.
Clearance between baulk ring and gear (1st, 3rd, main drive, OD and reverse baulk ring): Refer to image.
If the clearance is smaller than the wear limit, replace baulk ring.
- Measure wear of 2nd baulk ring.
a. Place baulk rings in position on synchronizer cone.
b. While holding baulk rings against synchronizer cone as far as it will go, measure dimensions "A" and "B".
Standard: Inner-A 0.7 - 0.9 mm (0.028 - 0.035 inch)
Outer-B 0.6 - 1.1 mm (0.024 - 0.043 inch)
Wear limit: 0.2 mm (0.008 inch)
- If dimension "A" or "B" is smaller than the wear limit, replace outer baulk ring, inner baulk ring and synchronizer cone as a set.