Part 1
Input Shaft and GearsDISASSEMBLY
1. Before disassembly, check 3rd, 4th and 5th input gear end plays.
Gear end play: Refer to Manual Transmission/Transaxle; Specifications.
- If not within specification, disassemble and check contact surface of gear, shaft and hub. Check clearance of snap ring groove. Refer to ASSEMBLY.
2. Remove input shaft rear bearing.
3. Remove 5th & reverse synchronizer and 5th input gear.
4. Remove thrust washer ring, 4th input gear thrust washers and 4th input gear.
5. Remove snap ring.
6. Remove 3rd & 4th synchronizer and 3rd input gear.
7. Remove input shaft front bearing.
INSPECTION
Gear and shaft
- Check shaft for cracks, wear or bending.
- Check gears for excessive wear, chips or cracks.
Synchronizer
- Check spline portion of coupling sleeves, hubs and gears for wear or cracks.
- Check baulk rings for cracks or deformation.
- Check insert springs for wear or deformation.
- Measure clearance between baulk ring and gear (3rd, 4th and 5th).
Clearance between baulk ring and gear:
Standard 1.0 - 1.35 mm (0.0394 - 0.0531 inch)
Wear limit 0.7 mm (0.028 inch)
- Measure wear of reverse baulk ring.
a. Place reverse baulk ring on Tool and then place reverse synchronizer cone on reverse baulk ring.
- Make sure projection of synchronizer cone is positioned over the recess on Tool.
b. While holding reverse synchronizer cone against reverse baulk ring as firmly as possible, measure dimension "A" with dial indicator.
Wear limit: Dimension "A" 1.2 mm (0.047 inch)
c. If dimension "A" is smaller than the wear limit, replace baulk ring.
Bearing
- Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
ASSEMBLY
1. Place inserts in three grooves on coupling sleeve (3rd & 4th synchronizer).
2. Install 3rd input gear and 3rd baulk ring.
3. Press on 3rd & 4th synchronizer hub.
- Pay attention to its direction.
4. Select proper snap ring of 3rd & 4th synchronizer hub to minimize clearance of groove, and then install it.
Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 inch)
Snap ring of 3rd & 4th synchronizer hub: Refer to Application and ID.
5. Install 4th input gear.
6. Select proper thrust washers to minimize clearance of groove. Then install them and thrust washer ring.
Allowable clearance of groove: 0 - 0.06 mm (0 - 0.0024 inch)
4th input gear thrust washer: Refer to Application and ID.
7. Install 5th & reverse synchronizer assembly.
a. Hook insert springs on reverse baulk ring.
b. Install insert springs with reverse baulk ring onto coupling sleeve.
- Pay attention to position of insert springs.
c. Place 5th baulk ring on 5th input gear.
d. Install reverse synchronizer cone on reverse baulk ring.
e. Place reverse synchronizer assembly on 5th input gear.
- Mesh recesses of 5th input gear with projections of reverse synchronizer cone.
- Put insert spring mounts on reverse baulk ring upon those on 5th baulk ring.
f. Press on 5th & reverse synchronizer assembly with 5th input gear.
8. Install input shaft front and rear bearings.
9. Measure gear end play as a final check. Refer to DISASSEMBLY.
Mainshaft and Gears
DISASSEMBLY
1. Before disassembly, check 1st and 2nd main gear end plays.
Gear end play: Refer to Manual Transmission/Transaxle; Specifications.
If not within specification, disassemble and check contact surface of gear, shaft and hub. Check clearance of snap ring groove. Refer to ASSEMBLY.
2. Press out mainshaft rear bearing.
3. Remove thrust washer and snap ring.
4. Press out 5th main gear and 4th main gear.
5. Press out 3rd main gear and 2nd main gear.
6. Remove snap ring.
7. Remove 1st & 2nd synchronizer hub and 1st main gear.
8. Remove mainshaft front bearing.
INSPECTION
Gear and shaft
- Check shaft for cracks, wear or bending.
- Check gears for excessive wear, chips or cracks.
Synchronizer
- Check spline portion of coupling sleeves, hubs and gears for wear or cracks.
- Check baulk rings for cracks or deformation.
- Check insert springs for deformation.
- Measure wear of 1st and 2nd double baulk rings.
a. Place baulk rings in position on synchronizer cone.
b. While holding baulk ring against synchronizer cone as far as it will go, measure dimensions "A" and "B".
Standard:
A 0.6 - 0.8 mm (0.024 - 0.031 inch)
B 0.6 - 1.1 mm (0.024 - 0.043 inch)
Wear limit: 0.2 mm (0.008 inch)
c. If dimension "A" or "B" is smaller than the wear limit, replace baulk ring.
Bearing
- Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
- When replacing tapered roller bearing, replace outer and inner race as a set.
ASSEMBLY
1. Press on 1st main gear, 1st baulk ring and 1st & 2nd synchronizer hub.
- Pay attention to direction of 1st & 2nd synchronizer hub.
2. Select proper snap ring of 1st & 2nd synchronizer hub to minimize clearance of groove and then install it.
Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 inch)
Snap ring of 1st & 2nd synchronizer hub: Refer to Application and ID.
3. Install 2nd synchronizer cone, inner & outer baulk rings. Insert springs and 1st & 2nd coupling sleeve.
4. Install 2nd main gear.
- Ensure four protrusions of 2nd synchronizer cone are set in holes of 2nd main gear.
5. Press on 3rd main gear.
6. Press on 4th main gear.
7. Press on 5th main gear.
8. Select proper snap ring of 5th main gear to minimize clearance of groove and then install it.
Allowable clearance of groove: 0 - 0.15 mm (0 - 0.0059 inch)
Snap ring of 5th main gear: Refer to Application and ID.
9. Press on thrust washer and press on mainshaft rear bearing.
10. Press on mainshaft front bearing.
11. Measure gear end play as a final check. Refer to DISASSEMBLY.
Final Drive
DISASSEMBLY
- RS5F150A -
1. Remove final gear.
2. Remove speedometer drive gear by cutting it.
3. Press out differential side bearings.
- Be careful not to mix up the right and left bearings.
4. Drive out retaining pin and draw out pinion mate shaft.
5. Remove pinion mate gears and side gears.
- RS5F50V -
1. Remove final gear.
2. Press out differential side bearings.
3. Remove speedometer drive gear.
4. Remove viscous coupling.
5. Separate differential cases. Make paint marks to identify their original positions.
6. Remove pinion mate shaft with gears.
INSPECTION
Gear, washer, shaft and case
- Check mating surfaces of differential case, viscous coupling, side gears and pinion mate gears.
- Check washers for wear.
Viscous coupling
- Check case for cracks.
- Check silicone oil for leakage.
Bearings
- Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
- When replacing taper roller bearing, replace outer and inner race as a set.