Primary Shaft Assembly

DISASSEMBLY AND INSPECTION
1. Measure thrust clearance of all gears before disassembly, refer to preinspection.





2. Assemble in order shown in figure.
3. Assembly will be in reverse order of disassembly.

Caution: Check thrust clearance of all gears before disassembly and after assembly.

PREINSPECTION
3rd gear thrust clearance





1. Measure the clearance between 3rd gear and 2nd gear.
Clearance: 0.0024 - 0.0083 inch (0.06 - 0.21 mm)
Maximum: 0.010 inch (0.26 mm)
2. If the clearance exceeds the maximum, check the contact surface of 3rd gear, 2nd gear and the clutch hub (2nd/3rd), replace worn or damaged parts.

4th gear side clearance





1. Measure the clearance between 4th gear and the ball bearing.
Clearance: 0.004 - 0.015 inch (0.1 - 0.37 mm)
Maximum: 0.022 inch (0.57 mm)
2. If the clearance exceeds the maximum, check the contact surface of 4th gear, the ball bearing and the clutch hub (3rd/4th), replace worn or damaged parts.

DISASSEMBLY

Caution: Hold the shaft with one hand so that it does not fall.





1. Remove the ball bearing with a SST (OK130 175 008).
2. Remove 4th gear.





3. Remove the retaining ring.
4. Remove the clutch hub assembly (3rd/4th), the synchronizer ring (3rd) and the 3rd gear.





5. Remove the bearing with a SST (OK670 990 AAO).

INSPECTION
Synchronizer ring
1. Inspect individual synchronizer ring teeth for damage, wear or cracks.





2. Inspect the taper surface for wear or cracks.

Notice: Set the synchronizer ring squarely in the gear then measure around the circumference.





3. Measure the clearance between the synchronizer ring and the flank surface of the gear.
Standard clearance: 0.0433 - 0.0551 inch (1.1 - 1.4 mm)
Minimum: 0.03 inch (0.8 mm)

Primary shaft

Notice: If the shaft gear is replaced, adjust the bearing preload.





1. Inspect the shaft gear runout.
Maximum runout: 0.004 inch (0.10 mm)
2. Inspect the splines for damage or wear.
3. Inspect the gear teeth surface for damage, wear or cracks.

3rd gear, 4th gear, 5th gear and gear sleeve (5th gear)





1. Measure the clearance between the shaft gears and gears.





1 of 2





2 of 2

Oil clearance inch (mm)

2. Inspect the 5th gear sleeve for damage.





3. Inspect the gear teeth surface for damage, wear or cracks.

Bearing





1. Inspect for damage or rough rotation.

ASSEMBLY
1. Assemble 3rd gear, the synchronizer ring and the clutch hub assembly.





2. Assemble the new retaining ring.
3. Assemble 4th gear.





4. Assemble the new ball bearing with press.

INSPECTION
Measurement of thrust clearance
If installation of the primary shaft is completely done, measure the thrust clearance.

Thrust clearance of 3rd gear





1. Measure the thrust clearance between 3rd gear and 2nd gear.
Clearance: 0.0024 - 0.0083 inch (0.06 - 0.21 mm)
Maximum: 0.01 inch (0.26 mm)

Thrust clearance of 4th gear





1. Measure the thrust clearance between 4th gear and the ball bearing.
Clearance: 0.0039 - 0.146 inch (0.1 - 0.37 mm)
Maximum: 0.022 inch (0.57 mm)
If not as specified, reassemble the primary shaft assembly.