Input Shaft and Gears
INPUT SHAFT AND GEARSDisassembly and Assembly
DISASSEMBLY
1. Before disassembling, measure the end play for 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 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.
4. Remove the snap ring.
5. Remove the 6th input gear, 6th bushing, and 6th needle bearing using Tool as shown.
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.
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.
10. Remove the 3rd needle bearing.
11. Remove the input shaft front bearing using Tool as shown.
INSPECTION AFTER DISASSEMBLY
Input Shaft and Gear
Inspect the components for the following conditions as shown. 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 below. 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
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
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: 0.7 mm (0.028 inch)
Bearing
Check the items below. If necessary, replace them with new ones.
^ Rough rotation of the bearing as shown.
^ Damage to the bearing.
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: Do not reuse the 3rd-4th synchronizer hub.
^ Install with orientation of the synchronizer hub as shown.
^ Install with orientation of coupling sleeve as shown.
^ Be sure not to hook the ends of the 2 spread springs (front and back have two each) on the same shifting insert.
4. Install 3rd-4th coupling sleeve assembly using Tool as shown.
CAUTION: Align the grooves of the shifting insert and the 3rd baulk ring.
5. Install the 4th bushing using Tool as shown.
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 thrust washer so that dimension C2 satisfies 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.
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:
^ Do not reuse the 5th-6th synchronizer hub.
^ Install with the orientation of the synchronizer hub as shown.
^ Be sure 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.
CAUTION: Align the grooves of the 5th-6th shifting insert and 5th-6th baulk ring.
14. Install the needle bearing, 6th input gear and then 6th bushing using Tool as shown.
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.
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.
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 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)