Part 1 of 2

Mainshaft Disassembly, Inspection, and Reassembly
1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
2. Inspect the splines for excessive wear and damage.
3. Check shaft bearing surface for scoring and excessive wear.
4. Before installing the O-rings, wrap the shaft splines with tape to prevent O-ring damage.
5. Lubricate all parts with ATF during assembly.
6. Install the conical spring washer, 41 x 68 mm thrust washer in the direction shown.
7. Replace the locknut and conical spring washer with new ones when assembling the transmission.
8. Check the clearance of the 5th gear.

Mainshaft 5th Gear Clearance Inspection
1. Remove the mainshaft transmission housing bearing.





2. Assemble 41 x 68 mm thrust washer (A), 4th/5th clutch (B), 4th gear collar (C), and transmission housing bearing (D) on the mainshaft (E). Do not install the O-rings during inspection.
3. Install the idler gear (F) on the mainshaft by a press, then install the conical spring washer (G) and locknut (H).
4. Tighten the locknut to 29 Nm (3.0 kgf-m, 22 ft. lbs.).





5. Measure the clearance between the mainshaft flange (A) and 41 x 68 mm thrust washer (B) with a feeler gauge (C) in at least three places. Use the average as the actual clearance.





6. If the clearance is out of standard, remove the 41 x 68 mm thrust washer and measure its thickness.
7. Select and install a new thrust washer, then recheck.





THRUST WASHER, 41 x 68 mm

8. After replacing the thrust washer, make sure the clearance is within standard.
9. Disassemble the shaft and gears.
10. Reinstall the bearing in the transmission housing.

Countershaft Disassembly, Inspection, and Reassembly





1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
2. Inspect the splines for excessive wear and damage.
3. Check shaft bearing surface for scoring and excessive wear.
4. Lubricate all parts with ATF during assembly.
5. Install the conical spring washer, reverse selector, 3rd gear, 5th gear, 1st gear, and 2nd gear in the direction shown.
6. Countershaft locknut has left-had threads.
7. Replace the locknut and conical spring washer with new ones when assembling the transmission.
8. Some reverse selector hubs, 4th gear collars, and 3rd gears are press-fitted to the countershaft; special tools are needed to remove them and install them.

Selector Hub, 4th Gear Collar, and 3rd Gear Removal

Special Tool Required
Bearing separator 07KAF-PS30200

NOTE:
- Some reverse selector hubs, 4th gear collars, and 3rd gears are not press-fitted, and can be removed without using the special tool and a puller.
- Place a shaft protector between the countershaft and a puller to prevent damaging the countershaft.





1. Remove the reverse selector hub (A) and 4th gear (B) with the special tool, a two-jaw (or three-jaw) puller (C), and a shaft protector (D).





2. Install the special tool by inserting it into the opening between the 3rd gear (A) and 4th gear collar (B). Set the puller (C) to the special tool, then remove the 4th near collar.
3. Remove the set ring.





4. Remove the 3rd gear (A) with the puller (B).

Selector Hub, 4th Gear Collar, and 3rd Gear Installation

Special Tools Required
- Driver 40 mm I.D. 07746-0030100
- Attachment, 35 mm I.D. 07746-0030400

NOTE: Some reverse selector hubs, 4th gear collars, and 3rd gears are not press-fitted, and can be installed without using the special tool and a press.

1. Assemble the 2nd gear, 1st gear, 5th gear, and distance collar on the countershaft.





2. Slide the 3rd gear (A) over the countershaft, and press it in place with the special tool and a press.
3. Install the set ring.





4. Install the 4th gear collar (A) with the special tools and a press.
5. Install the needle bearing and 4th gear.





6. Install the reverse selector hub (A) with the special tool and a press.

Secondary Shaft Disassembly, Inspection, and Reassembly





1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
2. Inspect the splines for excessive wear and damage.
3. Check shaft bearing surface for scoring and excessive wear.
4. Before installing the O-rings, wrap the shaft splines with tape to prevent O-ring damage.
5. Lubricate all parts with ATF during assembly.
6. Install the conical spring washer, idler gear in the direction shown.
7. Secondary shaft locknut has left-hand threads.
8. Replace the locknut and conical spring washer with new ones when assembling the transmission.
9. Check the clearance of 2nd gear and 1st gear.

Secondary Shaft Ball Bearing, Idler Gear Removal and Installation

Special Tool Required
Attachment, 42 mm I.D. 07QAD-P0A0100

Removal





Place a shaft protector (A) on the secondary shaft (B), and set the puller (C) under the idler gear (D), then remove the idler gear and ball bearing (E).

Installation





Install the idler gear (A) on the secondary shaft (B), and install the ball bearing (C) over the idler gear with the special tool and a press.

Secondary Shaft 2nd Gear Clearance Inspection





1. Install the thrust needle bearing (A), needle bearing (B), 2nd gear (C), thrust needle bearing (D), 37 x 58 mm thrust washer (E), and 2nd clutch (F) on the secondary shaft (G), then secure them with the snap ring (H)





2. Measure the clearance between the snap ring (A) and the 2nd clutch guide (B) with a feeler gauge (C), in at least three places. Use the average as the actual clearance.
STANDARD: 0.04 - 0.12 mm (0.002 - 0.005 inch)
3. If the clearance is out of standard, remove the 37 x 58 mm thrust washer and measure its thickness.
4. Select and install a new thrust washer, then recheck.





THRUST WASHER, 37 x 58 mm

5. After replacing the thrust washer, make sure the clearance is within standard.
6. Disassemble the shaft and gears.

Secondary Shaft 1st Gear Clearance Inspection

Special Tools Required
Attachment, 42 mm I.D. 07QAD-P0A0100





1. Install the thrust needle bearing (A), needle bearing (B), 1st gear (C), thrust needle bearing (D), 40 x 51.5 mm thrust washer (E), 1st/3rd clutch (F), and 3rd gear collar (G) on the secondary shaft (H).





2. Install the idler gear (I), then install the ball bearing (J) on the idler gear with the special tool and a press.
3. Install the conical spring washer (K) and locknut (L), then tighten the locknut to 29 Nm (3.0 kgf-m, 22 ft. lbs.).





4. Turn the secondary shaft assembly upside down, and set the dial indicator (A) on the 1st gear (B).





5. Hold the secondary shaft, and measure the 1st gear axial clearance in at least three places while moving the 1st gear (A). Use the average as the actual clearance.
6. If the clearance is out of standard, remove the 40 x 51.5 mm thrust washer and measure its thickness.
7. Select and install a new thrust washer, then recheck.





THRUST WASHER, 40 x 51.5 mm
8. After replacing the thrust washer, make sure the clearance is within standard.
9. Disassemble the shaft and gears.

Idler Gear Shaft Removal and Installation





1. Remove the snap ring (A), cotter retainer (B), and cotter keys (C). Do not distort the snap ring.
2. Remove the idler gear shaft/idler gear assembly (D) from the transmission housing.
3. Check the snap rings and cotter retainer for wear and damage. Replace them if they are worn, distorted, or damaged.
4. Install the idler gear and shaft in the reverse order of removal.

Idler Gear/Idler Gear Shaft Replacement

Special Tools Required
- Driver 07749-0010000
- Attachment, 32 x 35 mm 07746-0010100





1. Remove the snap ring from the idler gear/idler shaft assembly.





2. Remove the idler gear shaft (A) from the idler gear (B) with the special tools and a press.





3. Replace the idler gear or idler gear shaft, and attach the idler gear shaft to the idler gear.





4. Install the idler gear shaft (A) in the idler gear (B) with the special tools and a press.
5. Install the snap ring.