Input Shaft and Gears
INPUT SHAFT AND GEARSDisassembly and Assembly
DISASSEMBLY
1. Before disassembling, measure the end play for the 3rd, 4th, 5th, and 6th input gears.
End play standard values
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 the measurement is outside the standard value, disassemble to check the contact surfaces of the gear, shaft, and hub. Adjust using the correct size snap ring for assembly.
2. Remove the oil channel.
3. Remove the input shaft rear bearing using Tool as shown.
Tool number
A: Commercial service tool
B: ST33052000 ( - )
4. Remove the snap ring.
5. Remove the 6th input gear, 6th bushing, and 6th needle bearing using Tool as shown.
Tool number
A: Commercial service tool
B: ST33052000 ( - )
6. Remove the 6th baulk ring, 5th-6th coupling sleeve, and shifting insert.
7. Remove the 5th input gear and synchronizer hub assembly simultaneously using Tool as shown.
Tool number
A: KV40105020 ( - )
B: Commercial service tool
8. Remove the 5th needle bearing.
9. Remove the 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 using Tool as shown.
Tool number
A: ST33052000 ( - )
B: Commercial service tool
10. Remove the 3rd needle bearing.
11. Remove the input shaft front bearing using Tool as shown.
INSPECTION AFTER DISASSEMBLY
Input Shaft and Gear
^ Check the items listed. If necessary, replace them with new ones.
^ Damage, peeling, dent, uneven wear, or bending of the input shaft.
^ Excessive wear, damage, or peeling of the input gears.
Synchronizer
Check the items listed. If necessary, replace them with new ones.
^ Damage and excessive wear of the contact surfaces of coupling sleeve, synchronizer hub, and shifting insert.
^ Coupling sleeve and synchronizer hub must move smoothly as shown.
^ If any cracks, damage, or excessive wear is found on the cam face of baulk ring or working face of the insert as shown, replace it.
Baulk Ring Clearance for Single Cone Synchronizer (4th, 5th and 6th)
Press the 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
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: 0.7 mm (0.028 inch)
Baulk Ring Clearance for Double-cone Synchronizer (3rd)
^ Follow the instructions and inspect the clearance of the outer baulk ring, synchronizer cone, and inner baulk ring.
CAUTION: Outer baulk ring, synchronizer cone, and inner baulk ring act as a set to control the clearances "A" and "B". If the measurement exceeds the service limit value, replace all of them as a set.
1. Using a dial gauge and Tool, measure clearance "A" at two or more points diagonally opposite, and calculate mean value.
Tool number: ST30031000 (J-22912-01)
Clearance "A"
Standard: 0.6 - 0.8 mm (0.024 - 0.031 inch)
Limit value: 0.2 mm (0.008 inch)
2. Using a feeler gauge, measure clearance "B" at two or more points diagonally opposite, and calculate mean value as shown.
Clearance "B"
Standard: 0.6 - 1.1 mm (0.024 - 0.043 inch)
Limit value: 0.2 mm (0.008 inch)
Bearing
Check the item listed. If necessary, replace it with a new one.
^ Damage and rough rotation of the bearing as shown.
ASSEMBLY
1. Install the 3rd needle bearing.
2. Install the 3rd input gear and 3rd baulk ring.
3. Install the spread spring, shifting insert, and a new 3rd-4th synchronizer hub onto the 3rd-4th coupling sleeve.
CAUTION:
^ Install with the orientation of the new synchronizer hub as shown.
^ Do not reuse the 3rd-4th synchronizer hub.
^ Install with the orientation of the coupling sleeve as shown.
^ Do not hook the ends of the two spread springs (front and back have two each) on the same shifting insert.
4. Install the 3rd-4th synchronizer assembly using Tool as shown.
Tool number: KV40105710 ( - )
CAUTION: Align grooves of the shifting insert and 3rd baulk ring.
5. Install the 4th bushing using Tool as shown.
Tool number: KV40105710 ( - )
6. Install the 4th baulk ring.
7. Install the 4th input gear and 4th needle bearing.
8. Measure the dimension "C2 " as shown. Select a suitable thrust washer so that dimension "C2 " satisfies the standard dimension specification. Then install the thrust washer onto the input shaft.
Standard for dimension "C2": 154.7 - 154.8 mm (6.091 - 6.094 inch)
CAUTION: Only 1 thrust washer can be selected.
Thrust Washer
9. Install the 5th bushing using Tool as shown.
Tool number: KV40105710 ( - )
10. Install the 5th needle bearing and 5th input gear.
11. Install the 5th baulk ring.
12. Install the synchronizer assembly onto a new 5th-6th synchronizer hub.
CAUTION:
^ Install with the orientation of the new synchronizer hub as shown.
^ Do not reuse the 5th-6th synchronizer hub.
^ Do not to hook the ends of the 2 spread springs (front and back have two each) on the same shifting insert.
13. Install the 5th-6th synchronizer hub assembly using Tool as shown.
Tool number: KV40105710 ( - )
CAUTION: Align the grooves of the 5th-6th shifting insert and the 5th 6th baulk ring.
14. Install the needle bearing, 6th input gear and then 6th bushing using Tool as shown.
Tool number: ST33200000 (J-26082)
15. Install the snap ring onto the input shaft, and measure to check that end play (gap between snap ring and groove) of the 6th bushing is within specification.
End play standard value: 0 - 0.1 mm (0 - 0.004 inch)
^ If the measurement is outside the standard value, select the appropriate size snap ring.
Snap Rings
16. Install the input shaft rear bearing using Tool as shown.
Tool number: ST30901000 (J-26010-01)
CAUTION: Install input shaft rear bearing with its brown surface facing the input gear side.
17. Install the input shaft front bearing using Tool as shown.
Tool number
A: ST33052000 ( - )
B: ST30032000 (J-26010-01)
18. Install the oil channel onto the input shaft.
19. Check the end play of the 3rd, 4th, 5th and 6th input gears as shown.
End play standard values
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)