Disassembly
DISASSEMBLYPrecaution
1. Clean the transmission exterior thoroughly with steam or cleaning solvents or both, before disassembly.
2. Clean the removed parts with cleaning solvent, and dry with compressed air. Clean out all holes and passages with a compressed air, and check that there are no obstructions.
3. Wear eye protection when using compressed air to clean components.
1. Release bearing
2. Clutch release fork
3. Boot
4. Bolt
5. Front cover
6. Gasket
7. Adjustment shim(s)
8. Snap ring
9. Bolt
10. Control case
11. Extension housing Removal
12. Transmission case Removal
13. Snap rings
14. Speedometer drive gear
15. Ball
Extension housing
1. Move the control rod end to the neutral position.
2. Turn it and remove the extension housing.
Transmission case
Remove the transmission case from the intermediate housing and gear assembly with the SST.
1. Roll pins
2. Shift rod end (1st/2nd)
3. Shift rod end (3rd/4th)
4. Shift rod end (5th/reverse)
5. Intermediate housing
6. Roll pins
7. Cap plugs
8. Springs and balls
9. Shift rod (1st/2nd)
10. Shift fork (1st/2nd)
11. Shift rod (3rd/4th)
12. Shift fork (3rd/4th)
13. Shift rod (5th/reverse)
14. Shift fork (5th/reverse)
15. Interlock pins
1. Snap ring
2. Washer
3. Retaining ring
4. C washers
5. Ball bearing Removal
6. Retaining ring
7. C washers
8. Thrust lock washer
9. Ball
10. 5th gear
11. Synchronizer ring
12. Locknut
13. Ball bearing
14. Counter gear
15. Spacer
16. Clutch hub assembly (5th/reverse)
17. Reverse gear
18. Needle bearing
19. Inner race
20. Washer
21. Counter reverse gear
22. Reverse idle gear shaft
23. Washer
24. Reverse idle gear
25. Washer
26. Ball bearing
27. Ball bearing (front)
28. Bearing housing assembly Removal
29. Mainshaft and gear assembly
30. Main drive gear
31. Synchronizer ring
32. Countershaft gear
33. Spacer
Bearing Disassembly
1 Remove the snap ring, washer, retaining ring, and C washers; then remove the mainshaft rear bearing with the SST.
2. Remove the locknut (Refer to LOCKNUT BELOW) and the countershaft rear bearing with the SST.
3. Remove the main drive gear bearing from the transmission case with a suitable pipe.
4. Remove the countershaft front bearing with the SST.
Locknut
1. Shift the clutch hub sleeves to first gear and reverse gear to put the gears in the double-engaged condition.
2. Use a suitable tool to uncrimp the tabs of the locknut for 5th/reverse clutch hub.
3. Locknut for 5th/reverse clutch hub
(1) Secure the bearing housing in a vise
(2) Remove the locknut with the SST.
Caution:
(a) Do not reuse the locknut after it has been removed.
(b) Use pads in the vise.
4. Locknut for counter shaft rear bearing
(1) Connect the SST to the mainshaft, and mount them securely in a vise.
(2) Loosen the locknut and remove it.
Bearing housing assembly
1. Remove the bearing housing by lightly tapping the counter shaft with a copper hammer.
2. Remove the spacer.
Note: If bearing housing roller bearing is replaced, replace the spacer as a set.
1. Washer
2. 1st gear
3. Needle bearing
4. Inner race
5. Synchronizer ring (1st)
6. Clutch hub assembly (1st/2nd)
7. Synchronizer ring (2nd)
8. 2nd gear
9. Snap ring
10. Clutch hub assembly (3rd/4th)
11. Synchronizer ring (3rd)
12. 3rd gear
13. Mainshaft
14. Synchronizer key springs
15. Synchronizer key
16. Clutch hub
17. Clutch hub sleeve
Clutch hub assembly (3rd/4th)
1. Place the SST between 2nd gear and 3rd gear.
2. Support the mainshaft by hand to prevent it from falling, and press out the clutch hub assembly.
1. Bearing cover
2. Ball bearing
3. Adjustment shim
4. Roller bearing
5. Adjustment shim
6. Bearing housing
1. Control lever
2. Control rod end
3. 0il passage
4. Speedometer driven gear
5. Back-up light switch
6. Neutral switch
7. Pin
8. Oil seal, Do not remove if not necessary
9. Extension housing
10. Pin
11. Wave washer
12. Bushing