Gear Shift and Select Shaft Assembly and Fifth Gears

Disassembly





1. Remove gear shift interlock bolt (3) and 5th to REV interlock guide bolt (4) from transmission case.
2. Remove gear shift and select shaft assembly.
3. Remove 9 bolts and take off transmission side cover.

CAUTION: Care should be taken not to distort side cover when it is removed from left case.

4. Engage gear double meshing to loosen countershaft and input shaft nuts.
5. Remove shaft nuts and then hub plate.

NOTE: Do not hammer when loosening nuts.





6. Remove back up light switch (1).





7. Remove 5th shift fork plug (1) and guide ball (2).
8. Remove circlip (3) and C-ring (4).





9. Remove gear shift fork (2), sleeve and hub assembly (3), synchronizer ring spring, synchronizer ring and 5th gear all together. Gear puller (2) is required for this work.

CAUTION: Be careful not to pinch synchronizer ring spring when removing.





10. Remove input shaft 5th gear, needle bearing and then countershaft 5th gear (3). Gear puller (4) would be necessary if spline fitting of countershaft 5th gear is tight.
11. Remove bolts (1) and take off left case plate (2), and then bearing set shim.
12. Remove C-ring of input shaft L bearing.

Reassembly
Fifth gears





1. To seat countershaft L bearing cup (2) to bearing cone, tap cup by using special tool and plastic hammer.
Special tool (A): 09913-84510





2. Put a shim (3) on bearing cup (4) provisionally, place straightedge (1) over it and compress it by hand through straightedge, and then measure "a" (Clearance between case surface (5) and straightedge by using feeler gauge (6).
Clearance between case surface and straightedge (Shim protrusion) "a": 0.08 - 0.12 mm (0.0031 - 0.0047 inch)
3. By repeating Step 2, select a suitable shim which adjusts clearance "a" to specification and put it on bearing cup.

NOTE: Insert 0.1 mm (0.004 inch) feeler to know whether or not a shim fulfills specification quickly.

Available shim thickness 0.40, 0.45, 0.50, 0.55, 0.60, 0.65, 0.70, 0.75, 0.80, 0.85, 0.90, 0.95, 1.00, 1.05, 1.10 and 1.15 mm (0.015, 0.017, 0.019, 0.021, 0.023, 0.025, 0.027, 0.029, 0.031, 0.033, 0.035, 0.037, 0.039, 0.041, 0.043 and 0.045 inch)





4. Place left case plate (2) inserting its end in groove of shift guide shaft (4) and then tighten it with bolts (1) applied with thread lock cement.

NOTE: After tightening screws, make sure that countershaft can be rotated by hand feeling some load.

"A": Thread lock 1322 99000-32110
Tightening torque
Left case plate bolt (a): 23 Nm (2.3 kgf-m, 17.0 ft. lbs.)





5. Install countershaft 5th gear (1) to countershaft facing machined boss A inward.
6. Install needle bearing to input shaft, apply oil then install input shaft 5th gear (2).





7. Engage gear double meshing to tighten countershaft nut and tighten it to specified torque.
Tightening torque
Countershaft nut (a): 70 Nm (7.0 kgf-m, 51.0 ft. lbs.)





8. Assemble 5th speed synchronizer sleeve (4) and hub (3) with keys (2) and springs (1).

NOTE: Short side C in keys, long boss D in hub and chamfered spline F in sleeve should face inward (5th gear side).

9. Install synchronizer ring to input shaft 5th gear.





10. Fit 5th gear shift fork (1) to sleeve and hub assembly and install them into input shaft, gear shift shaft and gear shift guide shaft at once aligning hub depression A, shaft mark B and synchronizer key C.

NOTE: Long boss of hub faces inward (gear side).





11. Install steel ball (2), tighten shift fork plug (1) applied with thread lock cement.

CAUTION:
^ Coat shift fork plug with thread lock cement reasonably. If it is done too much, excess coating may interfere in ball movement and cause hard shift to 5th speed.
^ Make sure circlip (3) is installed in shaft groove securely.

"A": Threadlock 1322 99000-32110
Tightening torque
5th shift fork plug (a): 9 Nm (0.9 kgf-m, 6.5 ft. lbs.)
12. Install circlip and C-ring (4).





13. Install 5th synchronizer hub plate (1) to synchronizer hub (2) by positioning it so that its lugs A fit into their depression B in synchronizer hub and its 2 small holes C come on the same side as cut D in input shaft.





14. Engage gear double meshing to tighten input shaft nut (1) and tighten it to specified torque.
Tightening torque
Input shaft nut (a): 70 Nm (7.0 kgf-m, 51.0 ft. lbs.)
15. Caulk input shaft nut and countershaft nut (2) with caulking tool.





16. Clean mating surface of both left case (2) and side cover (1), coat mating surface with sealant evenly, mate it with left case and then tighten with 8 bolts.
"B": Bond No.1215 99000-31110
Tightening torque
Left cover bolt (a): 10 Nm (1.0 kgf-m, 7.5 ft. lbs.)

Gear shift and select shaft assembly
1. Clean mating surface of guide case.
2. Install gear shift and select shaft assembly with new gasket into transmission.
3. Place breather hose bracket and tighten it together with gear shift guide case bolts (2) to specified torque.
Tightening torque
Gear shift guide case bolt (a): 19 Nm (1.9 kgf-m, 14.0 ft. lbs.)
4. Install washer and gear shift interlock bolt (3) applied with thread lock cement and them tighten it to specified torque.
"A": Thread lock cement (BOND No.1322) 99000-32110
Tightening torque
Gear shift interlock bolt (b): 23 Nm (2.3 kgf-m, 17.0 ft. lbs.)
5. Install washer and 5th to REV interlock guide bolt (4) applied with thread lock cement and then tighten it to specified torque.
"A": Thread lock cement (BOND No.1322) 99000-32110
Tightening torque
5th to REV interlock guide bolt (b): 23 Nm (2.3 kgf-m, 17.0 ft. lbs.)





6. Tighten back up light switch (1) to specified torque.
Tightening torque
Back up light switch (c): 20 Nm (2.0 kgf-m, 14.5 ft. lbs.)
7. Check input shaft for rotation in each gear position.
8. Also confirm function of back up light switch in reverse position by using ohmmeter.