Part 2 of 2
Main Shaft AssemblyASSEMBLY
1) Assemble each sleeve & hub assembly.
NOTE:
Position the open ends of spring 120° apart.
2) Install the 3rd drive gear, outer baulk ring, synchro cone, inner baulk ring, sleeve & hub assembly for 3rd needle bearing on transmission main shaft.
NOTE:
Align the groove in baulk ring with shifting insert.
3) Install the 4th needle bearing race onto transmission main shaft using ST1, ST2 and a press.
NOTE:
Do not apply pressure in excess of 10 kN (1 ton, 1. 1 US ton, 1.0 Imp ton).
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
4) Install the baulk ring, needle bearing, 4th drive gear and 4th gear thrust washer to transmission main shaft.
NOTE:
^ Align the baulk ring and gear & hub assembly with key convex portion.
^ Be careful with the direction of thrust washer.
5) Drive the ball bearing onto the rear section of transmission main shaft using ST1, ST2 and a press.
NOTE:
Do not apply pressure in excess of 10 kN (1 ton, 1. 1 US ton, 1.0 Imp ton).
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
6) Using the ST1 and ST2, install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft.
NOTE:
^ Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
^ Face the thrust washer in correct direction.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
7) Install the bearing onto synchro cone.
8) Install the baulk ring and synchro cone onto 5thRev sleeve & hub assembly using ST and a press.
NOTE:
^ Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
^ Use a new ball bearing.
^ After press fitting, make sure the synchro cone rotates freely.
ST 499757002 INSTALLER
9) Install the synchro cone stopper and snap ring to 5th-Rev sleeve & hub assembly.
10) Install the rest parts to the rear section of transmission main shaft.
NOTE:
Align the groove in baulk ring with shifting insert.
11) Tighten the lock nuts to the specified torque using ST1 and ST2.
NOTE:
Secure the lock nuts in two places after tightening.
ST1 499987003 SOCKET WRENCH (35)
ST2 498937000 TRANSMISSION HOLDER
Tightening torque:
120 Nm (12.2 kgf-m, 88.5 ft. lbs.)
INSPECTION
Disassembled parts should be washed clean first and then inspected carefully.
1) Bearings
Replace the bearings in the following cases:
^ Bearings whose balls, outer races and inner races are broken or rusty.
^ Worn bearings
^ Bearings that fail to turn smoothly or make noise when turned after gear oil lubrication.
^ Bearings having other defects
2) Bushing (each gear)
Replace the bushing in the following cases:
^ When the sliding surface is damaged or abnormally worn.
^ When the inner wall is abnormally worn.
3) Gears
^ Replace the gears with new ones if their tooth surfaces are broken, damaged, or excessively worn.
^ Correct or replace if the cone that contacts the baulk ring is rough or damaged.
^ Corrector replace if the inner surface or end face is damaged.
4) Baulk ring Replace the ring in the following cases:
^ When the inner surface and end face are damaged.
^ When the ring inner surface is abnormally or partially worn down.
^ When the contact surface of the synchronizer ring insert is scored or abnormally worn down.
5) Shifting insert key
Replace the insert if deformed, excessively worn or defective in any way.
6) Oil seal
Replace the oil seal if the lip is deformed, hardened, damaged, worn or defective in any way.
7) O-ring
Replace the O-ring if the sealing face is deformed, hardened, damaged, worn or defective in any way.
8) Gearshift mechanism
Repair or replace the gearshift mechanism if excessively worn, bent or defective in any way.
ADJUSTMENT
Selection of main shaft rear plate:
Using the ST, measure the amount (A) of ball bearing protrusion from transmission main case surface and select the proper plate in the following table.
NOTE:
Before measuring, tap the end of main shaft with a plastic hammer lightly in order to make the clearance zero between the main case surface and the moving flange of bearing.
ST 498147000 DEPTH GAUGE
