16. Fifth Gears Assembly
Fifth Gears Assembly
1. To seat countershaft left 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 straight edge (1) over it and compress it by hand through straight edge, and then measure "a" (Clearance between case surface (5) and straight edge) by using feeler gauge (6).
Clearance between case surface and straight edge "a": 0.08 - 0.12 mm (0.0032 - 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 countershaft 5th gear shim thickness 0.55 mm (0.021 inch) 0.7 mm (0.027 inch) 0.85 mm (0.033 inch) 1.0 mm (0.039 inch) 0.6 mm (0.023 inch) 0.75 mm (0.029 inch) 0.9 mm (0.035 inch) 1.05 mm (0.041 inch) 0.65 mm (0.025 inch) 0.8 mm (0.031 inch) 0.95 mm (0.037 inch) 1.1 mm (0.043 inch)
4. Place left case plate (2) inserting its end in groove of shift guide shaft (4) and then tighten bolts (1) to which thread lock cement has been applied.
NOTE: After tightening bolts, make sure that countershaft can be rotated by hand feeling certain load.
"A": Thread lock cement 99000-32110
Tightening torque
Left case plate bolts (a): 23 Nm (2.3 kgf-cm, 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-cm, 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 splice "F" in sleeve should face inward (5th gear side).
Synchronizer key installation position "A"="B"
9. Install synchronizer ring (2) to input shaft 5th gear.
10. Fit 5th gear shift fork (1) to sleeve (3) & hub (4) assembly and install them into input shaft, gear shift 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) to which thread lock cement has been applied.
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.
"A": Thread lock cement 99000-32110
Tightening torque
5th shift fork plug (a): 9 Nm (0.9 kgf-cm, 6.5 ft. lbs.)
12. Install circlip (3) 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.
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-cm, 51.0 ft. lbs.)
15. Caulk input shaft nut (1) and countershaft nut (2) with caulking tool "A".
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 bolts.
"B": Sealant 99000-31230
Tightening torque
Side cover bolts (a): 10 Nm (1.0 kgf-cm, 7.5 ft. lbs.)