RS6F51H

INPUT SHAFT AND GEARS
DISASSEMBLY





1. Before disassembling, measure end play for 3rd, 4th, 5th and 6th input gears.
End play standard value
3rd gear: 0.18 - 0.31 mm (0.0071 - 0.0122 inch)
4th gear: 0.20 - 0.30 mm (0.0079 - 0.0118 inch)
5th gear: 0.06 - 0.16 mm (0.0024 - 0.0063 inch)
6th gear: 0.06 - 0.16 mm (0.0024 - 0.0063 inch)

CAUTION: If measurement is outside the standard range, disassemble to check contact surfaces of gear, shaft, and hub. Adjust with snap ring at assembly.





2. Remove oil channel.
3. Remove input shaft rear bearing.
4. Remove the snap ring.





5. Remove 6th input gear, 6th bushing and 6th needle bearing.
6. Remove 6th baulk ring, 5th-6th coupling sleeve and shifting insert.





7. Remove 5th input gear and synchronizer hub assembly simultaneously.
8. Remove 5th needle bearing.





9. Remove 5th bushing, thrust washer, 4th input gear, 4th needle bearing, 4th bushing, 4th baulk ring, 3rd-4th synchronizer hub assembly, 3rd baulk ring and 3rd input gear simultaneously.
10. Remove 3rd needle bearing.





11. Remove input shaft front bearing.

INSPECTION AFTER DISASSEMBLY
Input Shaft and Gear





Check items below. If necessary, replace them with new ones.
- Damage, peeling, dent, uneven wear, or bending of shaft.
- Excessive wear, damage, or peeling of gears.

Synchronizer





Check items below. If necessary, replace them with new ones.
- Damage and excessive wear of contact surfaces of coupling sleeve, synchronizer hub, and shifting insert.
- Coupling sleeve and synchronizer hub must move smoothly.





- If any crack, damage, or excessive wear is found on cam face of baulk ring or working face of insert, replace it.

Baulk ring clearance





- Press baulk ring against cone, and measure clearance between baulk ring and cone. If measurement is below limit, replace it with a new one.
Clearance
Standard
3rd and 4th: 0.9 - 1.45 mm (0.035 - 0.0571 inch)
5th and 6th: 0.95 - 1.4 mm (0.0374 - 0.055 inch)
Limit value: 0.7 mm (0.028 inch)

Bearing





Check items below. If necessary, replace them with new ones.
- Damage and rough rotation of bearing

ASSEMBLY
1. Install 3rd needle bearing.
2. Install 3rd input gear and 3rd baulk ring.
3. Install spread spring, shifting insert and 3rd-4th synchronizer hub onto 3rd-4th coupling sleeve.





CAUTION:
- Be careful with orientation of synchronizer hub.





- Be careful with orientation of coupling sleeve.





- Be sure not to hook ends of 2 spread springs (front and back: 2 each) on same shifting insert.





4. Install 3rd-4th synchronizer hub assembly.

CAUTION: Align grooves of shifting insert and 3rd baulk ring.





5. Install 4th bushing.
6. Install 4th baulk ring.
7. Install 4th input gear and 4th needle bearing.





8. Select thrust washer so that dimension "C2" satisfies standard below. Then install it onto input shaft.
Standard for dimension C2: 154.7 - 154.8 mm (6.091 - 6.094 inch)





Thrust Washer

CAUTION: Only 1 thrust washer can be selected.





9. Install 5th bushing.
10. Install 5th needle bearing and 5th input gear.
11. Install 5th baulk ring.
12. Install synchronizer assembly onto 5th-6th synchronizer hub.





CAUTION:
- Be careful with orientation of synchronizer hub.





- Be sure not to hook ends of 2 spread springs (front and back: 2 each) on same shifting insert.





13. Install 5th-6th synchronizer hub assembly.

CAUTION: Align grooves of 5th-6th shifting insert and 5th-6th baulk ring.





14. Install needle bearing, 6th input gear and then 6th bushing.





15. Install snap ring onto input shaft, and check that end play (gap between snap ring and groove) of 6th bushing meets specification.
End play standard value: 0 - 0.1 mm (0 - 0.004 inch)
- If measurement is outside the standard range, select snap ring.





Snap Rings





16. Install input shaft rear bearing.

CAUTION: Install input shaft rear bearing with its brown surface facing the input gear side.





17. Install input shaft front bearing.
18. Install oil channel onto input shaft.





19. Check end play of 3rd, 4th, 5th and 6th input gears.
End play standard value
3rd gear: 0.18 - 0.31 mm (0.0071 - 0.0122 inch)
4th gear: 0.20 - 0.30 mm (0.0079 - 0.0118 inch)
5th gear: 0.06 - 0.16 mm (0.0024 - 0.0063 inch)
6th gear: 0.06 - 0.16 mm (0.0024 - 0.0063 inch)