Main Shaft Assembly
Main Shaft AssemblyReference: Manual Transmission Assembly Dismounting and Remounting
Reference: Manual Transmission Unit Disassembly
Reference: Main Shaft Disassembly
Reference: Main Shaft Inspection
NOTE:
^ Before installation, wash each part and apply specified gear oil to sliding faces of bearing and gear
^ Use new circlips on shaft for installation. Don't reuse circlips.
1. Assembly high speed synchronizer hub (3), sleeve (4), springs (1) and keys (2) according to the following procedure.
a. Install synchronizer springs (1) and synchronizer keys (2) to high speed synchronizer hub (3) as shown in the figure.
b. Slide hub (3) in sleeve (4) so that chamfered side of sleeve (4) and small diameter boss side of hub (3) face opposite as shown in the figure, also aligning hub slots with key location teeth of sleeve (4).
2. Assembly 3rd gear (1), synchronizer inner ring (2), synchronizer cone ring (4) and synchronizer outer ring according to the following procedure.
a. Install the synchronizer inner ring (2) to 3rd gear (1).
b. Install synchronizer cone ring (4) to 3rd gear (1).
NOTE: Fit protrusion (5) of synchronizer cone ring (4) into groove (3) of 3rd gear.
c. Install synchronizer outer ring (1) to 3rd gear (2).
d. Align protrusion (1) of synchronizer outer ring into slot (2) of synchronizer hub, and then attach high speed synchronizer sleeve and hub assembly to 3rd gear (3). Also align protrusion (4) of synchronizer inner ring and dent (5) of high speed synchronizer hub.
3. Install needle bearing (2) to main shaft (1) and press fit 3rd gear high speed synchronizer sleeve and hub assembly (3), which was assembled in step a) through d), to main shaft (1) using special tool and hydraulic press.
4. Select circlip (1) that will make thrust clearance of high speed synchronizer hub 0.1 mm (0.0039 inch) or less and install it.
Circlip thickness specifications
Circlip thickness specifications:
5. After installing circlip, check that 3rd gear turns lightly.
6. Check 3rd gear (2) thrust clearance using thickness gauge (1). If clearance is out of specification, repress-fit or replace.
7. Assemble low speed synchronizer hub (3), sleeve (4), springs (1) and keys (2) according to the following procedure.
a. Install synchronizer springs (1) and synchronizer keys (2) to low speed synchronizer hub (3) as shown in the figure.
b. Slide low speed synchronizer hub (3) in sleeve (4) so that flange side of sleeve (4) and small diameter boss side of hub (3) face opposite as shown the figure, also aligning hub slots with key location teeth of sleeve (4).
8. Assemble 2nd gear (1), synchronizer inner ring (2), synchronizer cone ring (3) and synchronizer outer ring according to the following procedure.
a. Install synchronizer inner ring (2) to 2nd gear (1).
b. Install synchronizer cone ring (4) to 2nd gear (1).
NOTE: Fit protrusion (4) of synchronizer cone ring (4) into groove (3) of 2nd gear.
c. Install synchronizer outer ring (1) to 2nd gear (2).
d. Install 2nd gear (3), fitting slot (1) of low speed synchronizer hub in protrusion (2) of synchronizer outer ring as shown in the figure. Also align protrusion (4) of synchronizer inner ring and dent (5) of low speed synchronizer hub.
9. Install the needle bearing to the 2nd gear, then as the figure shows press fit 2nd gear low speed synchronizer sleeve and hub assembly (1), which was assembled in step a) through d), into main shaft (2) using special tool. Press-fit low speed sleeve and hub assembly with special tool and hydraulic press (3).
10. Select circlip (1) that will make thrust clearance of low speed synchronizer hub 0.1 mm (0.0039 inch) or less and install it.
Circlip thickness specifications
Circlip thickness specifications:
Special Tool
(A): 09900-06107
11. Check 2nd gear thrust clearance, referring to Main Shaft Assembly.
12. Install spacer (1) and needle bearing (2) to main shaft (3).
13. Install synchronizer outer ring (1) to low speed synchronizer hub (2).
NOTE: Fit protrusion (3) of synchronizer outer ring (1) into groove (4) of low speed synchronizer hub (2).
14. Install synchronizer cone ring (1) and synchronizer inner ring (2).
NOTE: Fit protrusion (3) of synchronizer inner ring (2) into dent (4) of low speed synchronizer hub (5).
15. Install low gear (1) to main shaft (2).
NOTE:
^ Fit protrusion (3) of synchronizer cone ring (5) into groove (4) of low gear (1).
^ After installation, check synchronizer outer ring (5) moves in circumferential direction.
16. Install pin (1) and low gear thrust washer (2) to main shaft.
NOTE: Check the cut in low gear thrust washer and pin are engaged.
17. Press-fit main shaft bearing (1) and 5th gear (3) with special tool and hydraulic press (2).
NOTE:
^ Bring bearing so that its groove for circlip is in the rear.
^ Bring 5th gear (3) so that its small diameter boss a is in the rear.
Special Tool
(C): 09940-51710
18. Select circlip (1) that will make its thrust clearance 0.1 mm (0.0039 inch) or less and install it.
Circlip thickness specifications
Circlip thickness specifications:
19. Check low gear clearance referring to Main Shaft Assembly.