Input Shaft
DISASSEMBLY AND REASSEMBLY
Disassembly Service Points
Ball Bearing Removal
Reverse Brake Sleeve Removal
Mount the special tool on the 5th speed gear and remove the reverse brake sleeve.
Reassembly Service Points
>A< Oil Seal Installation
>B< Ball Bearing Installation
>C< Snap Ring Installation
Select and install a snap ring so that the input shaft front bearing clearance will have the standard value.
Standard value: -0.01 to 0.12 mm (-0.0004 to 0.0047 inch)
>D< Synchronizer Spring Installation
Install the synchronizer spring to the illustrated position of the synchronizer ring.
>E< 3rd-4th Speed Synchronizer Hub Installation
Install the 3rd-4th speed synchronizer hub so that it will be oriented in the direction shown.
CAUTION: When installing the hub, check that the synchronizer ring is not caught.
>F< Synchronizer Sleeve Installation
1. Install the synchronizer sleeve so that it will be oriented in the direction shown.
2. When the synchronizer sleeve is installed, check that the deep groove portion of the synchronizer hub is aligned with the projecting portion of the sleeve.
>G< 4th Speed Gear Sleeve Installation
>H< 5th Speed Gear Sleeve Installation
>I< 5th Speed Gear Installation
>J< 5th Speed-Reverse Synchronizer Hub Installation
CAUTION: When installing the 5th-reverse speed synchronizer hub, check that the synchronizer ring is not caught.
>K< Synchronizer Sleeve Installation
1. Install the synchronizer sleeve so that the identification grooves are oriented in the direction shown.
2. When the synchronizer sleeve is installed, check that the deep groove portion of the synchronizer hub is aligned with the projecting portion of the sleeve.
>L< Thrust Plate Installation
Select and install a thrust plate so that the input shaft 5th speed gear end play has the standard value.
Standard value: -0.01 to 0.09 mm (-0.0004 to 0.0035 inch)
CAUTION: Assemble with the identification stamp surface on the thrust plate stopper side.
>M< Reverse Brake Sleeve Installation
>N< Thrust Plate Stopper Installation
When the thrust plate is installed, check that it is not tilted.
>O< Ball Bearing Installation
>P< Snap Ring Installation
Select and install a snap ring so that the input shaft rear bearing clearance will have the standard value.
Standard value: 0 to 0.12 mm (0 to 0.0047 inch)
INSPECTION
Input Shaft
1. Check the outside diameter of the needle bearing mounting portion for damage, abnormal wear and seizure.
2. Check the splines for damage and wear.
Needle Roller Bearing
1. Check that when the input shaft, sleeve and gear are combined and made to rotate, they rotate smoothly without noise.
2. Check to ensure that the cage is not deformed.
Synchronizer Ring
1. Check to ensure that the clutch gear tooth surfaces are not damaged and broken.
2. Check to ensure that the cone inside diameter is not damaged or worn and that the threads are not crushed.
3. Press the synchronizer ring against the gear and check clearance "A." If "A" is less than the limit, replace.
Limit: 0.5 mm (0.020 inch)
Synchronizer Sleeve And Hub
1. Check that when the synchronizer sleeve and hub are combined and made to slide, they slide smoothly without binding.
2. Check to ensure that the front and rear ends of the sleeve inside surface are not damaged.
CAUTION: When replacement of either the synchronizer sleeve or hub is necessary, check that the synchronizer sleeve and hub are replaced as a set.
Synchronizer Spring
Check to ensure that the spring is not sagging, deformed or broken.
Speed Gears
1. Check to ensure that the helical and clutch gear tooth surfaces are not damaged or worn.
2. Check to ensure that the synchronizer cone surfaces are not roughened, damaged or worn.
3. Check to ensure that the gear inside diameter and front and rear surfaces are not damaged and worn.