Part 2
INPUT SHAFT DISASSEMBLY AND REASSEMBLY
Disassembly Service Points
Front Taper Roller Bearing Removal
CAUTION:
1. Do not reuse the bearing removed from the shaft.
2. Replace the inner and outer races of the taper roller bearing as a set.
Bearing Sleeve For 5Th Speed Gear Removal
CAUTION:
1. Do not reuse the bearing removed from the shaft.
2. Replace the inner and outer races of the taper roller bearing as a set.
Reassembly Service Points
>A< 3Rd-4Th Speed Synchronizer Hub / 3Rd-4Th Speed Synchronizer Sleeve Installation
>B< Synchronizer Spring / Synchronizer Key Installation
1. When installing the synchronizer springs, be sure to position each spring with respect to the keys as illustrated.
>C< Bearing Sleeve For 4Th Speed Gear Installation
>D< Sub Gear / Cone Spring / Snap Ring Installation
>E< Rear Taper Roller Bearing Installation
>F< Snap Ring Installation
1. Select the thickest snap ring that can be fitted in the snap ring groove.
Standard value:
Input shaft rear bearing end play 0.01-0.09 mm (0.0004-0.0035 inch)
CAUTION:
1. Do not reuse the snap ring.
2. The snap ring may be opened too wide by pliers, resulting in improper installation of the sleeve.
>G< Bearing Sleeve For 5Th Speed Gear Installation
CAUTION: When press-fitting the sleeve to the input shaft, make sure that the sleeve flange is closely fitted to the bearing.
>H< Front Taper Roller Bearing Installation
INPUT SHAFT INSPECTION
Input Shaft
1. Check the outer surface of the input shaft where the needle bearing is mounted for damage, abnormal wear and seizure [portion A].
2. Check the splines for damage and wear.
Needle Bearing
1. Combine the needle bearing with the shaft or bearing sleeve and gear and check that it rotates smoothly without abnormal noise or play.
2. Check the needle bearing cage for deformation.
Synchronizer Ring
1. Check the clutch gear teeth for damage and breakage.
2. Check the internal surface for damage, wear and broken threads.
3. Force the synchronizer ring toward the clutch gear and check clearance "A". Replace if it is out of specification.
Limit: 0.5 mm (0.020 inch) or less
Synchronizer Sleeve And Hub
1. Combine the synchronizer sleeve and hub and check that they slide smoothly.
2. Check that the sleeve is free from damage at its inside front and rear ends.
3. Check for wear of the hub end surfaces (in contact with each speed gear).
CAUTION: When replacing, replace the synchronizer hub and sleeve as a set.
Synchronizer Key And Spring
1. Check for wear of the synchronizer key center protrusion.
2. Check the spring for weakness, deformation and breakage.
Speed Gears
1. Check the synchronizer cone for rough surface, damage and wear.
2. Check the gear bore and front and rear ends for damage and wear.
INTERMEDIATE GEAR DISASSEMBLY AND REASSEMBLY
Disassembly Service Points
Taper Roller Bearing / 1st Speed Gear Removal
CAUTION:
1. Do not reuse the bearing removed from the shaft.
2. Replace the inner and outer races of the taper roller bearing as a set.
1st-2nd Speed Synchronizer Hub / 2nd Speed Gear Removal
CAUTION:
1. Do not reuse the bearing removed from the shaft.
2. Replace the inner and outer races of the taper roller bearing as a set.
Reassembly Service Points
>A< Taper Roller Bearing Installation
>B< 1st-2nd Speed Synchronizer Hub / Synchronizer Key /1st-2nd Synchronizer Sleeve Installation
1. Combine the 1st-2nd speed synchronizer hub and sleeve as illustrated.
2. The synchronizer sleeve has tooth missing at six portions. Assemble the hub to the sleeve in such a way that the center tooth "T" between two missing teeth will touch the synchronizer key.
>C< Synchronizer Spring Installation
1. When installing the synchronizer springs, be sure to position each spring with respect to the keys as illustrated.
>D< Bearing Sleeve Installation
>E< Taper Roller Bearing Installation
>F< Snap Ring Installation
1. Select and install the snap ring that gives standard intermediate gear bearing end play.
Standard value:
Intermediate gear bearing end play: 0.01-0.14 mm (0.0004-0.0055 inch)
INTERMEDIATE GEAR INSPECTION
Intermediate Gear
1. Check the outer surface of the intermediate gear where the needle bearing is mounted for damage, abnormal wear and seizure [portion (A)].
2. Check the splines for damage and wear.
Needle Bearing
1. Combine the needle bearing with the shaft or bearing sleeve and gear and check that it rotates smoothly without abnormal noise or play.
2. Check the needle bearing cage for deformation.
Synchronizer Ring
1. Check the clutch gear teeth for damage and breakage.
2. Check the internal surface for damage, wear and broken threads.
3. Force the synchronizer ring toward the clutch gear and check clearance "A". Replace if it is out of specification.
Limit: 0.5 mm (0.020 inch) or less
Synchronizer Outer Ring, Inner Ring And Cone
1. Check that there are no scratches of damage on the clutch gear teeth and cone surface.
2. Check that there are no scratches, wear or peeling on the paper lining surface.
3. Install the outer ring, inner ring and cone, and press them onto the clutch gear. Check clearance "A", and replace if "A" is below the limit value.
Limit: 0.5 mm (0.020 inch) or less
CAUTION: Replace the outer ring, inner ring and cone as a set.
Synchronizer Sleeve And Hub
1. Combine the synchronizer sleeve and hub and check that they slide smoothly.
2. Check that the sleeve is free from damage at its inside front and rear ends.
3. Check for wear of the hub end surface (in contact with each speed gear).
CAUTION: When replacing, replace the synchronizer hub and sleeve as a set.
Synchronizer Key And Spring
1. Check for wear of the synchronizer key center protrusion.
2. Check the spring for weakness, deformation and breakage.
Speed Gears
1. Check the bevel gear and clutch gear teeth for damage and wear.
2. Check the synchronizer cone for rough surface, damage and wear.
3. Check the gear bore and front and rear ends for damage and wear.
OUTPUT SHAFT DISASSEMBLY AND REASSEMBLY
Disassembly Service Points
Taper Roller Bearings Removal
CAUTION:
1. Do not reuse the bearings removed from the shaft.
2. Replace the inner and outer races of the taper roller bearing as a set.
Reassembly Service Points
>A< Taper Roller Bearings Installation
DIFFERENTIAL DISASSEMBLY AND REASSEMBLY
Disassembly Service Points
Taper Roller Bearing Removal
CAUTION:
1. Do not reuse the bearing removed from the shaft.
2. Replace the inner and outer races of the taper roller bearing as a set.
Lock Pin Removal
1. Drive out the lock pin from the hole A using a punch.
Reassembly Service Points
>A< Lock Pin Installation
1. Align the pinion shaft lock pin hole with the case lock pin hole and insert the new lock pin.
CAUTION:
1. Do not reuse the lock pin.
2. The lock pin must not protrude more than 3 mm (0.118 inch).
>B< Taper Roller Bearings Installation
>C< Bolts Installation
1. Apply the specified sealant to the bolt threads.
Specified sealant: 3M Stud Locking No.4170 or equivalent
2. Tighten to the specified torque while following the order given in the illustration.
DIFFERENTIAL INSPECTION
Adjustment Of Pinion Backlash
Measure the backlash between the side gears and pinions. Adjust for same backlash of both side gears.
Standard value: 0.025-0.150 mm (0.00098-0.00591 inch)
If backlash is out of specification, disassemble again and using correct spacer, reassemble and adjust.
SHIFT FORK DISASSEMBLY AND REASSEMBLY
Reassembly Service Point
>A< Interlock Plunger Installation
SPEEDOMETER GEAR DISASSEMBLY AND REASSEMBLY
Reassembly Service Points
>A< Speedometer Driven Gear Installation
1. Apply gear oil sparingly to the speedometer driven gear shaft and insert the shaft.
CLUTCH HOUSING DISASSEMBLY AND REASSEMBLY
Disassembly Service Points
Lock Pin Removal
CAUTION: When removing the lock pin, turn the control lever to such position that the lock pin will not contact the clutch housing.
Spring Pin Removal
CAUTION: When removing the spring pin, pull the control shaft in the direction illustrated so that the spring pin will not contact the clutch housing.
Reassembly Service Points
>A< Needle Bearings Installation
1. Install the needle bearing flush with the surface A of the clutch housing using a socket wrench.
2. Install with the part type stamped side facing the surface A.
>B< 0il Seal Installation
>C< Spring Pin Installation
CAUTION:
1. Do not reuse the spring pin.
2. Install the spring pin in such a way its slit will be at right angle to the control shaft center.