Output Shaft
DISASSEMBLY AND REASSEMBLY
Disassembly Service Points
Ball Bearing Removal
2nd Speed Gear Sleeve Removal
Reassembly Service Points
>A< Roller Bearing Inner Race Installation
>B< Snap Ring Installation
Select and install a snap ring so that the output shaft front bearing clearance will have the standard value.
Standard value: 0 to 0.12 mm (0 to 0.0047 inch)
>C< 1st Speed Gear Sleeve Installation
>D< Synchronizer Spring Installation
Install the synchronizer spring to the illustrated position of the synchronizer ring.
>E< 1st-2nd Speed Synchronizer Hub Installation
CAUTION: When installing the hub, check that the synchronizer ring is not caught.
>F< 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.
>G< Synchronizer Spring Installation
Install the synchronizer spring to the illustrated position of the outer synchronizer ring.
>H< 2nd Speed Gear Sleeve Installation
>I< 3rd Speed Gear Installation
>J< Snap Ring Installation
Select and install a snap ring so that the output shaft 3rd speed gear end play will have the standard value.
Standard value: -0.01 to 0.09 mm (-0.0004 to 0.0035 inch)
>K< 4th Speed Gear Installation
>L< 5th Speed Gear Sleeve Installation
>M< 5th Speed-Reverse Synchronizer Hub Installation
CAUTION: When the 5th speed-reverse synchronizer hub is installed, check that the synchronizer ring is not caught.
>N< Reverse Gear/Needle Roller Bearing/Reverse Gear Bearing Sleeve Installation
>O< Ball Bearing Installation
NOTE: Install the ball bearings so that the groove on the bearing snap ring faces upward.
>P< Snap Ring Installation
Select and install a snap ring so that the output shaft rear bearing clearance will have the standard value.
Standard value: -0.01 to 0.09 mm (-0.0004 to 0.0035 inch)
INSPECTION
Output Shaft
Check the splines for damage and wear.
Needle Roller Bearing
1. Check that when the bearing sleeve and gear are combined and made to rotate, they rotate smoothly without looseness and 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)
Outer Synchronizer Ring/Inner Synchronizer Ring/Synchronizer Cone
1. Check to ensure that the clutch gear tooth surfaces and cone surfaces are not damaged and broken.
2. Install the outer ring, inner ring and cone, press them against the gear, and check clearance "A." If "A" is less than the limit, replace.
Limit: 0.5 mm (0.020 inch)
CAUTION: When the outer ring, inner ring or cone has to be replaced, check that the outer ring, inner ring and cone are replaced as a set.
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.