Input Shaft and Gears
INPUT SHAFT AND GEARSDisassembly and Assembly
DISASSEMBLY
1. Before disassembling, measure end play for 3rd, 4th, and 5th 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)
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.
Tool number
A: ST33052000 ( - )
B: Commercial service tool
4. Remove the snap ring.
5. Remove input shaft bearing spacer and 5th stopper simultaneously.
Tool number
A: ST33052000 ( - )
B: Commercial service tool
6. Remove 5th input gear and synchronizer hub assembly simultaneously.
Tool number
A: KV40105020 ( - )
B: Commercial service tool
7. Remove 5th needle bearing.
8. Remove 5th bushing, thrust washer, 4th input gear, 4th needle bearing, 4th gear bushing, 4th baulk ring, 3rd-4th synchronizer hub assembly, 3rd gear synchronizer assembly, and 3rd input gear simultaneously.
Tool number
A: ST33052000 ( - )
B: Commercial service tool
9. Remove 3rd needle bearing.
10. Remove input shaft front bearing.
INSPECTION AFTER DISASSEMBLY
Input Shaft and Gears
Check items. If necessary, replace them with new ones. Damage, peeling, dent, uneven wear, bending, etc. of shaft Excessive wear, damage, peeling, etc. of gears
Synchronizer
Check items. 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 for Single Cone Synchronizer (4th and 5th)
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 value 4th: 0.8 - 1.45 mm (0.035 - 0.057 inch)
5th: 0.95 - 1.4 mm (0.037 - 0.055 inch)
Limit value: 0.7 mm (0.028 inch)
Baulk Ring Clearance for Double Cone Synchronizer (3rd)
Follow the instructions and inspect the clearance of outer baulk ring, synchronizer cone, inner baulk ring.
CAUTION: Outer baulk ring, synchronizer cone, and inner baulk ring determine the clearances "A" and "B" as an assembly. Replace the outer baulk ring, synchronizer cone and inner baulk ring as an assembly if either of the clearances "A" or "B" exceed the limit value.
Measure clearance "A" at two or more points diagonally opposite using a dial indicator, and calculate average value. Tool number A: ST30031000 (J-22912-01)
Clearance "A"
Standard value: 0.6 - 0.8 mm (0.024 - 0.031 inch)
Limit value: 0.2 mm (0.008 inch)
Measure clearance "B" at two or more points diagonally opposite using a feeler gauge, and calculate average value.
Clearance "B"
Standard value: 0.6 - 1.1 mm (0.024 - 0.043 inch)
Limit value: 0.2 mm (0.008 inch)
Bearing
^ Check items. 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 gear synchronizer assembly.
3. Install spread shrine shifting insert and 3rd-4th synchronizer hub onto 3rd-4th coupling sleeve.
CAUTION:
^ Be careful with orientation of synchronizer hub.
^ Do not reuse the 3rd-4th synchronizer hub.
^ Be careful with orientation of coupling sleeve.
^ Be sure not to hook ends of 2 spread springs (front and back have two each) on same shifting insert.
4. Install 3rd-4th synchronizer hub assembly.
Tool number: KV40105710 ( - )
CAUTION: Align grooves of shifting insert and 3rd baulk ring.
5. Install 4th bushing.
Tool number: KV40105710 ( - )
6. Install 4th baulk ring.
7. Install 4th input gear and 4th needle bearing.
8. Select thrust washer so that dimension "C2" satisfies standard. Then install it onto input shaft.
Standard for dimension "C2 ": 154.7 - 154.8 mm (6.091 - 6.094 inch)
Thrust Washer
CAUTION: Only one thrust washer can be selected.
9. Install 5th bushing.
Tool number: KV40105710 ( - )
10. Install 5th needle bearing and 5th input gear.
11. Install 5th baulk ring.
12. Install spread spring, shifting insert and 5th synchronizer hub onto 5th coupling sleeve.
CAUTION:
^ Be careful with orientation of synchronizer hub and shifting insert.
^ Be careful with orientation of coupling sleeve.
^ Be sure not to hook ends of 2 spread springs (front and back have two each) on same shifting insert.
13. Install 5th synchronizer hub assembly.
Tool number: KV40105710 ( - )
CAUTION: Align grooves of 5th shifting insert and 5th baulk ring.
14. Install 5th stopper and then input shaft bearing spacer.
Tool number: ST30032000 (J-26010-01)
15. Install snap ring onto input shaft, and check that end play (gap between snap ring and groove) of input shaft bearing spacer satisfies standard.
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.
Tool number: ST30901000 (J-26010-01)
CAUTION: Install input shaft rear bearing with its brown surface facing the input gear side.
17. Install input shaft front bearing.
Tool number
A: ST33052000 ( - )
B: ST30032000 (J-26010-01)
18. Install oil channel onto input shaft.
19. Check end play of 3rd, 4th, and 5th 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)