Part 1 2WD

TRANSMISSION UNIT
REMOVAL





1. Remove clutch release bearing (1).
2. Remove 8 clutch housing bolts (2) and then remove clutch housing (3).





3. Remove 8 bolts and pull out input shaft bearing retainer (1) by using large size screwdrivers (2) and clean cloth (3).

CAUTION: When pulling out, do not scratch the transmission case surface contacting with the clutch housing.





4. Remove 10 bolts and separate cases (1) and (2) by using special tool (A).

Special Tool
(A): 09912-34510

5. Take out input 3 and main shaft assembly.





6. Remove bearing circlip (1) at the rear part of counter shaft (2).





7. Using special tool (B), remove rear bearing (1).

Special Tool
(B): 09913-60910

8. Pull out 5th gear (2) and then reverse gear one at a time from counter shaft by hand.





9. Remove bolt (1) for reverse idle gear shaft (2) and then remove idle gear (3) and shaft as a set.





10. Remove center bearing plate (1) by removing its 2 bolts (3).





11. Remove outside circlip (1) of front bearing (2) on counter shaft.





12. Using plastic hammer (1), drive counter shaft (2) rearward, pull out roller bearing (3) by hand and then remove shaft from the front by pulling it up.





13. Remove circlip (1) of counter shaft front bearing (2) and pull out bearing by using special tool (B).

Special Tool
(B): 09913-60910

14. Remove circlip, friction gear spring, friction gear retainer pin and friction gear in that order.

INSPECTION AND INSTALLATION OF COUNTER SHAFT





1. Install friction gear (1), friction gear spring (2), friction gear retainer (3), pin (4) and circlip (5) in that order.





2. Check tooth surface of gear and rotation of bearing and replace with new one if necessary.
As long as no abnormal condition such as noise exists before removal, replacement is unnecessary.





3. Press-fit front bearing (1) and fit circlip.

Special Tool
(C): 09913-84510





4. With shaft (2) inserted into case, install roller bearing outer race (1) on it and then press-fit shaft by using special tool (D) and hammer.
Meanwhile case should be supported on wood blocks.

Special Tool
(D): 09951-16080





5. Fit circlip (1) around front bearing (2) and check to make sure that circlip just contacts with case surface.





6. Install bearing plate (1) applying thread lock cement to its bolts (2).

Cement: 99000-32020

Tightening Torque
(a): 6 Nm (0.6 kg-m, 4.0 ft. lbs.)





7. Install reverse idle gear (1) together with needle bearing (2) and thrust washer (3) on shaft and fix them with bolt from outside of case.

NOTE: Be sure to use aluminum washer (4) for bolt.

Tightening Torque
(b): 22 Nm (2.2 kg-m, 16.0 ft. lbs.)

8. Install reverse gear (5) and 5th gear (6) on counter shaft.





9. After press-fitting counter shaft rear bearing (1), make sure to fit circlip securely.

Special Tool
(E): 09913-80112

INPUT SHAFT-MAIN SHAFT ASSEMBLY
Input Shaft





1. Take out oil seal (1) from input shaft oil seal retainer (2) and install new oil seal with special tool (A) and hammer up to case surface.
Unless oil seal is leaky or its lip is excessively hardened, replacement is unnecessary.

Special Tool
(A): 09913-84510





2. Remove circlip of input shaft (1) and pull out bearing (2) with puller (3) and press as necessary.

NOTE: Sealed bearing must not be washed. Replace it with new one when required.





3. When installing bearing (1), bring it so that its groove for circlip is in the front and press-fit with special tool (B) and press.

Special Tool
(B): 09925-18010





4. After fitting circlip (1), air-blow lubrication oil hole.

DISASSEMBLY OF MAIN SHAFT





1. After removing needle bearing for input shaft at the front end of main shaft, pull out high speed sleeve from its hub and remove 3 synchronizer keys.
2. Remove circlip in front of hub and pull off hub (1) with special tool (A), then take out synchronizer springs.

Special Tool
(A): 09913-61510

3. Remove 3rd synchronizer ring (2), 3rd gear (3) and needle bearing.

NOTE: High speed sleeve-hub assembly, synchronizer ring and 3rd gear can be removed all at once by using puller and hydraulic press.





4-1. After removing circlips, pull off speedometer drive gear (1).





4-2. After removing circlips, pull off rear bearing (1) with puller (2) and press.
5. Remove thrust washer and steel ball and then remove 5th gear, synchronizer ring and needle bearing.
6. Pull out reverse sleeve from its hub and remove 3 synchronizer keys.





7. Remove circlip and pull off reverse hub (1) from main shaft with puller (2) and press, then take out synchronizer springs.

NOTE: It is also possible to remove reverse sleeve-hub as assembly and reverse gear all at once by using puller and press, after removing circlip.

8. Remove main shaft reverse gear and needle bearing by hand.





9. Using puller (3) and press, remove reverse gear bush (1) and bearing washer (2).

NOTE: During above work, watch out for steel ball which will come out from inside of washer so as not to lose it.

CAUTION: Do not attempt to pull out bearing, washer and bush all together at once. Steel ball would stop bearing and cause damage to it.





10. Pull off bearing (1) with puller and press.
11. Remove the following in that order: bearing washed steel ball, low gear, low synchronizer, needle bearing and low gear bush.





12. Using puller (1) and press, pull out low speed sleeve and hub assembly (2), 2nd gear (3) and 2nd synchronizer ring all together.

NOTE: If bush (4) can't be pulled out by hand at step 11, pull off sleeve and hub together by using press.

13. Remove sleeve from hub and then take off synchronizer keys and springs.

INSPECTION OF MAIN SHAFT INNER PARTS





1. Check each ball bearing for smooth rotation and replace with new one, if necessary.





2. Inspect needle bearings and needle contacting surfaces (rotating surfaces) and replace with new ones as required.

NOTE: Should abnormal noise be heard before disassembly, it is necessary to carefully check needle contacting surface inside of each gear besides those parts shown in figure.





3. Check clearance "a" between synchronizer ring and gear, key slot width "b" in synchronizer ring and each chamfered tooth of gear and synchronizer ring and replace with new one, if necessary. Also, check gear tooth.

Clearance "a":
Standard 1.0 -1.4 mm (0.039 - 0.055 inch)
Service limit 0.5 mm (0.019 inch)
Slot width "b":
Standard 10.1 mm (0.397 inch)
Service limit 10.4 mm (0.409 inch)





4. Check chamfered part of each sleeve of) for damage and excessive wear, and replace as necessary.
5. Using feeler gauge, check clearance between sleeve and shifter fork Ad) and replace parts if necessary.

Clearance "c": Maximum 1.0 mm (0.039 inch)

6. Check each synchronizer key and synchronizer spring and replace as necessary.
7. Check splined portions and replace parts if excessive wear are found.

ASSEMBLING MAIN SHAFT





NOTE:
- Before installation, wash each part and apply specified gear oil to sliding faces of bearing and gear.
- Use new circlips on shaft for reinstallation. Don't reuse used circlips





1. Fit sleeve (2) to low speed hub (1), place 3 synchronizer keys (3) in it and set synchronizer spring (4).
Refer to figure for proper installing direction of hub, sleeve and springs. Synchronizer key has no specific direction for installation.

NOTE: When installing each synchronizer spring, insert its hooked end to hub hole and put it toward right.





2. Install needle bearing (1), 2nd gear (2) and 2nd synchronizer ring to main shaft (3).





3. Press-fit sleeve and hub assembly (1) onto main shaft (2) with press.

Special Tool
(A): 09927-08210





4. Insert low gear bush (1) and set synchronizer ring (2) needle bearing (3) and low gear (4).





5. Set steel ball (1) and washer (2).





6. Using special tools and press, press-fit bearing (1).

Special Tools
(B): 09925-18010
(C): 09927-08210
(D): 09940-53111





7. Fit sleeve (1) to reverse hub (2), place 3 synchronizer keys (3) in it and then set synchronizer springs (4).
Refer to figure for proper installing direction of hub, sleeve and springs. Also, note that key has specific installing direction.





8. Set steel ball and bearing washer (1) and insert reverse gear bush (2), needle bearing (3) and reverse gear (4).





9. Press-fit reverse sleeve and hub assembly (1) with special tool and press.

Special Tools
(B): 09925-18010
(C): 09927-08210
(D): 09940-53111





10. After setting large circlip (1), install 5th speed synchronizer ring, needle bearing, 5th gear (2), steel ball (3) and washer (4).

NOTE: Washer should be installed with its oil slot side facing gear.





11. Press-fit bearing (1) with special tool (B) and fit small circlip.

Special Tool
(B): 09925-18010





12. Fit small circlip (1), using special tool (D), fit speedometer drive gear (2) and then fit the other small circlip.

Special Tool
(D): 09951-16080





13. Fit sleeve (1) to high speed hub (2), place 3 synchronizer keys (3) and set synchronizer springs (4) as shown. Neither sleeve nor key has specific installing direction.





14. Install needle bearing, 3rd gear (3) and 3rd synchronizer ring (2). Then using special tool (E) and press, press-fit high speed sleeve and hub assembly (1) onto shaft.

Special Tool
(E): 09913-84510

15. Fit large circlip.
16. Install needle bearing.