Part 2

5. REMOVE REVERSE GEAR, SHIFTING KEY AND SPRING FROM CLUTCH HUB NO.1
a. Remove the reverse gear from the clutch hub No. 1.
b. Push the shifting key spring with a screwdriver, remove the 3 shifting keys and key springs.

6. REMOVE HUB SLEEVE NO.2 ASSEMBLY AND 3RD GEAR ASSEMBLY
a. Using a snap ring expander, remove the snap ring.
b. Using a press, remove the hub sleeve No.2 assembly and 3rd gear assembly.
c. Remove the needle roller bearing.
7. REMOVE SHIFTING KEY AND SPRING FROM HUB SLEEVE NO.2 ASSEMBLY
Using a screwdriver, remove the 3 shifting keys and 2 springs.

Inspection
1. INSPECT OUTPUT SHAFT

a. Using a micrometer, measure the output shaft flange thickness.

Minimum thickness: 4.70 mm (0.1850 inch)

If the thickness is less than the minimum, replace the output shaft.

b. Using a micrometer, measure the outer diameter of the output shaft journal.

Minimum diameter:
A 1st gear: 38.860 mm (1.5299 inch)
B 2nd gear: 46.860 mm (1.8449 inch)
C 3rd gear: 37.860 mm (1.4905 inch)

If the outer diameter is less than the minimum, replace the output shaft.

c. Using a dial indicator, check the shaft runout.

Maximum runout: 0.06 mm (0.0024 inch)

If the runout exceeds the maximum, replace the output shaft.
2. INSPECT 1ST AND 3RD GEARS SYNCHRONIZER RING

a. Check for wear or damage.
b. Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.

NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.

c. Check again the braking effect of the synchronizer ring.

d. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.

Minimum clearance: 0.8 mm (0.031 inch)

If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone.

NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.

3. INSPECT 2ND GEAR SYNCHRONIZER RING
a. Check for wear or damage.

b. Install the synchronizer inner ring, middle ring and outer ring to each gear.

c. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
If it does not lock, replace the synchronizer ring.

4. INSPECT SHIFT FORK AND HUB SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.

Maximum clearance: 1.0 mm (0.039 inch)

If the clearance exceeds the maximum, replace the shift fork or hub sleeve.

Reassembly

HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.

1. INSTALL CLUTCH HUB NO.2 INTO HUB SLEEVE NO.2
a. Install the clutch hub No.2 and shifting keys to the hub sleeve No.2.
b. Install the shifting key springs under the shifting keys.

NOTICE: Position the key springs so that their end gaps are not aligned.

2. INSTALL CLUTCH HUB NO.1 INTO REVERSE GEAR

a. Install the 3 shifting key springs to the clutch hub No.1.
b. While pushing the shifting key spring with a screwdriver, install the 3 shifting keys.

c. While pushing the 3 shifting keys, install the clutch hub No.1 to the reverse gear, as shown.
3. INSTALL 3RD GEAR AND HUB SLEEVE NO.2 ON OUTPUT SHAFT

a. Apply gear oil to the shaft and needle roller bearing.
b. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
c. Install the needle roller bearing in the 3rd gear.

d. Using a press, install the 3rd gear and hub sleeve No.2.

4. INSTALL SNAP RING

a. Select a snap ring that allows the minimum axial play.
b. Using a snap ring expander, install the snap ring.
5. INSPECT 3RD GEAR THRUST CLEARANCE
6. INSTALL 2ND GEAR AND REVERSE GEAR
a. Apply gear oil to the shaft and needle roller bearing.
b. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
c. Align the projection of the synchronizer inner ring with the slots of the clutch hub No.1.
d. Install the needle roller bearing in the 2nd gear.

e. Using a press, install the 2nd gear assembly and reverse gear assembly.

7. INSTALL SNAP RING

a. Select a snap ring that allows the minimum axial play.
b. Using a screwdriver and hammer, install the snap ring.

8. INSTALL SPACER AND 1ST GEAR ASSEMBLY
a. Install the spacer on the output shaft.
b. Apply gear oil to the needle roller bearing.
c. Assemble the 1st gear, synchronizer ring and needle roller bearing.
d. Install the assembly on the output shaft with the synchronizer ring slots aligned with the shifting keys.

9. INSTALL STRAIGHT PIN AND 1ST GEAR THRUST WASHER
Install the 1st gear thrust washer onto the output shaft with the straight pin aligned with the 1st gear thrust washer.

10. INSTALL OUTPUT SHAFT CENTER BEARING
a. 2WD: Using SST and a hammer, drive in the bearing with the outer race snap ring groove toward the rear.
SST 09309-35010
b. 4WD: Using SST and a hammer, drive in the bearing with the outer race snap ring groove toward the rear.
SST 09316-60011 (09316-00011, 09316-00071)
11. INSPECT 1ST GEAR THRUST CLEARANCE
12. INSPECT 2ND GEAR THRUST CLEARANCE

13. INSTALL 5TH GEAR
Using SST and a press, install the 5th gear.
SST 09316-60011 (09316-00031)

COUNTER GEAR AND REVERSE IDLER GEAR

Components

Disassembly
REMOVE HUB SLEEVE NO.3, SHIFTING KEY AND SPRING FROM SYNCHRONIZER RING

a. Remove the synchronizer ring assembly from the hub sleeve No.3.
b. Turn the reverse synchronizer pull ring.

c. Remove the reverse synchronizer ring and 5th synchronizer ring from the synchronizer pull ring and cone ring.

d. Turn the reverse synchronizer pull ring, separate the pull ring and cone ring.
e. Push the shifting key and spring, and remove the 3 shifting keys and springs to the reverse synchronizer ring.

Inspection

1. INSPECT 5TH GEAR RADIAL CLEARANCE
a. Install the spacer, counter 5th gear and needle roller bearings.
b. Using a dial indicator, measure the counter 5th gear radial clearance.

Standard clearance: 0.015 - 0.068 mm (0.0006 - 0.0027 inch)
Maximum clearance: 0.160 mm (0.0063 inch)

If the clearance exceeds the maximum, replace the gear bearing or shaft.

2. INSPECT COUNTER GEAR
Using a micrometer, measure the outer diameter of the counter gear journal.

Minimum diameter: 27.860 mm (1.0968 inch)

If the outer diameter is less than the minimum, replace the counter gear.
3. INSPECT 5TH SYNCHRONIZER RING
a. Check for wear or damage.

b. Install the synchronizer pull ring, cone ring and outer ring to the gear spline piece No.5.

5. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE
Using a dial indicator, measure the reverse idler gear radial clearance.

Standard clearance: 0.040 - 0.082 mm (0.0016 - 0.0032 inch)
Maximum clearance: 0.130 mm (0.0051 inch)

If the clearance exceeds the maximum, replace the reverse idler gear or reverse idler gear shaft.

6. INSPECT REVERSE IDLER GEAR AND SHIFT ARM CLEARANCE
Using a feeler gauge, measure the clearance between the reverse idler gear and shift arm.

Standard clearance: 0.05 - 0.35 mm (0.0020 - 0.0138 inch)
Maximum clearance: 0.50 mm (0.0197 inch)

If the clearance exceeds the maximum, replace the shift arm or reverse idler gear.

Replacement
IF NECESSARY, REPLACE COUNTER GEAR FRONT BEARING

a. Using a snap ring expander, remove the snap ring.
b. Using SST and a press, remove the bearing.
SST 09950-00020
c. Replace the side race.

d. Using a socket wrench and press, install a new bearing and side race.

e. Select a snap ring that allows the minimum axial play.

f. Using a snap ring expander, install the snap ring.

Reassembly
INSTALL SYNCHRONIZER RING ASSEMBLY TO HUB SLEEVE NO.3

a. Put the key spring to the hole of the shifting key.
b. Push the 3 shifting keys with the 3 key springs to the reverse synchronizer ring.
c. Install the synchronizer cone ring to the reverse synchronizer pull ring and turn the pull ring.

d. Install the 5th synchronizer ring.
e. Install the reverse synchronizer ring.

f. Turn the reverse synchronizer pull ring.

g. While pushing the 3 shifting keys, install the synchronizer ring assembly to the hub sleeve No.3.

FRONT BEARING RETAINER OIL SEAL

Components

Replacement
IF NECESSARY, REPLACE FRONT BEARING RETAINER OIL SEAL

a. Using a screwdriver, pry out the oil seal.

b. Using SST and a hammer, drive in a new oil seal.
SST 09950-60010 (09951-00510), 09950-70010 (09951-07150)

Drive in depth: 11.7 ± 0.5 mm (0.461 ± 0.020 inch) from retainer end

EXTENSION HOUSING AND TRANSFER ADAPTOR

Components

Replacement
1. IF NECESSARY, REPLACE REVERSE RESTRICT PIN

a. Remove the reverse restrict pin.
1) Using a torx socket wrench (T40), remove the screw plug.
2) Using a pin punch and hammer, drive out the slotted spring pin.
3) Remove the reverse restrict pin.
b. Inspect the reverse restrict pin.
Turn and push the reverse restrict pin by hand.
Check for smooth operation.

c. Install the reverse restrict pin.
1) Install the reverse restrict pin to the extension housing or transfer adapter.
2) Using a pin punch and hammer, drive in the slotted spring pin, as shown.
3) Apply sealant to the plug threads.

Sealant: Part No. 08833 - 00080, THREE BOND 1344, LOCTITE 242 or equivalent

4) Using a torx socket wrench (T40), install and torque the screw plug.

Torque: 19 Nm (190 kgf-cm, 14 ft. lbs.)

2. 2WD: IF NECESSARY, REPLACE EXTENSION HOUSING OIL SEAL
a. Remove the dust deflector.
b. Using a screwdriver, pry out the oil seal.

c. Using SST and a hammer, drive in a new oil seal.
SST 09950-60010 (09951-00570), 09950-70010 (09951-07150)

Drive in depth: 0 ± 0.5 mm (0 ± 0.020 inch)

d. Install the deflector.

3. 4WD: IF NECESSARY, REPLACE TRANSFER ADAPTOR OIL SEAL
a. Using a screwdriver, pry out the oil seal.
b. Using SST and a hammer, drive in a new oil seal.
SST 09950-60010 (09951-00570), 09950-70010 (09951-07150)

Drive in depth: 45.6 ± 0.5 mm (1.795 ± 0.020 inch)