Part 1

INPUT SHAFT

Components:

DISASSEMBLY
1. INSPECT 6TH GEAR THRUST CLEARANCE

a) Using a dial indicator, measure the 6th gear thrust clearance.
Standard clearance: 0.20 to 0.48 mm (0.0079 to 0.0189 inch)
If the clearance is outside the specification, replace the defective gear, thrust washer or shaft.

2. INSPECT 3RD GEAR THRUST CLEARANCE

a) Using a feeler gauge, measure the 3rd gear thrust clearance.
Standard clearance: 0.19 to 0.51 mm (0.0075 to 0.0201 inch)
If the clearance is outside the specification, replace the defective gear, thrust washer, clutch hub or shaft.

3. REMOVE 4TH GEAR THRUST CLEARANCE

a) Using a dial indicator, measure the 4th gear thrust clearance.
Standard clearance: 0.12 to 0.38 mm (0.0047 to 0.0150 inch)
If the clearance is outside the specification, replace the defective gear, clutch hub or shaft.

4. INSPECT 6TH GEAR RADIAL CLEARANCE

a) Using a dial indicator, measure the 6th gear radial clearance.
Standard clearance: 0.015 to 0.065 mm (0.0006 to 0.0026 inch)
If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.

5. INSPECT 3RD GEAR RADIAL CLEARANCE

a) Using a dial indicator, measure the 3rd gear radial clearance.
Standard clearance: 0.015 to 0.067 mm (0.0006 to 0.0026 inch)
If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.

6. INSPECT 4TH GEAR RADIAL CLEARANCE

a) Using a dial indicator, measure the 4th gear radial clearance.
Standard clearance: 0.015 to 0.067 mm (0.0006 to 0.0026 inch)
If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.

7. REMOVE NO.3 TRANSMISSION CLUTCH HUB SHAFT SNAP RING

a) Using 2 screwdrivers and a hammer, tap out the snap ring.

HINT: Use a shop rag or a piece of cloth to prevent the snap ring from flying off.

8. REMOVE 6TH GEAR

a) Using SST and a press, remove the No.3 transmission clutch hub, hub sleeve, synchronizer ring and 6th gear from the input shaft.
SST 09950-00020, 09950-70010 (09951-07200), 09950-60010 (09951-00300)

NOTICE:
^ Do not tighten SST excessively.
^ Support the input shaft by hand so that it does not fall off.

9. REMOVE 6TH GEAR NEEDLE ROLLER BEARING

a) Remove the 6th gear needle roller bearing from the input shaft.

10. REMOVE SPACER

a) Remove the spacer from the input shaft.

11. REMOVE GEAR THRUST WASHER SHAFT SNAP RING

a) Using a snap ring expander, remove the snap ring from the input shaft.

12. REMOVE 3RD GEAR THRUST WASHER

a) Remove the 3rd gear thrust washer from the input shaft.

13. REMOVE 3RD GEAR

a) Remove the 3rd gear from the input shaft.

14. REMOVE STRAIGHT PIN

a) Remove the straight pin from the input shaft.

15. REMOVE 3RD GEAR NEEDLE ROLLER BEARING

a) Remove the 3rd gear needle roller bearing from the input shaft.

16. REMOVE SPACER

a) Remove the spacer from the input shaft.

17. REMOVE NO.2 SYNCHRONIZER RING SET

a) Remove the No.2 synchronizer ring set from the input shaft.

18. REMOVE NO.2 CLUTCH HUB SETTING SHAFT SNAP RING

a) Using a snap ring expander, remove the snap ring from the input shaft.

19. REMOVE 4TH GEAR

a) Using SST and a press, remove the No.2 transmission clutch hub, hub sleeve, synchronizer ring and 4th gear from the input shaft.
SST 09950-00020

NOTICE: Support the input shaft by hand so that it does not fall off.

20. REMOVE 4TH GEAR NEEDLE ROLLER BEARING

a) Remove the 4th gear needle roller bearing from the input shaft.

21. REMOVE INPUT SHAFT FRONT BEARING SNAP RING

a) Using 2 screwdrivers and a hammer, tap out the snap ring.

HINT: Use a shop rag or a piece of cloth to prevent the snap ring from flying off.

22. REMOVE INPUT SHAFT FRONT BEARING

a) Using SST and a press, remove the input shaft front bearing from the input shaft.
SST 09950-00020

NOTICE: Support the input shaft by hand so that it does not fall off.

23. REMOVE NO.2 TRANSMISSION CLUTCH HUB

a) Remove the clutch hub, 3 synchromesh shifting keys, 3 balls and 3 springs from the hub sleeve.

HINT: Use a shop rag or a piece of cloth to prevent the ball and spring from flying off.

24. REMOVE NO.3 TRANSMISSION CLUTCH HUB

a) Perform the same procedures as for the No.2 transmission clutch hub.

INSPECTION
1. INSPECT INPUT SHAFT
a) Using a dial indicator and 2 V-blocks, measure the shaft runout.
Maximum runout: 0.03 mm (0.0012 inch)
If the runout exceeds the maximum, replace the input shaft.

b) Using a micrometer, measure the outer diameter of the input shaft journal surface.

Standard:

Minimum:

If the outer diameter is less than the minimum, replace the input shaft.

2. INSPECT 6TH GEAR

a) Using a cylinder gauge, measure the inside diameter of the 6th gear.
Standard inside diameter: 51.015 to 51.040 mm (2.0085 to 2.0095 inch)
Maximum inside diameter: 51.040 mm (2.0095 inch)
If the inside diameter exceeds the maximum, replace the 6th gear.

3. INSPECT 3RD GEAR

a) Using a cylinder gauge, measure the inside diameter of the 3rd gear.
Standard inside diameter: 51.015 to 51.040 mm (2.0085 to 2.0095 inch)
Maximum inside diameter: 51.040 mm (2.0095 inch)
If the inside diameter exceeds the maximum, replace the 3rd gear.

4. INSPECT 4TH GEAR

a) Using a cylinder gauge, measure the inside diameter of the 4th gear.
Standard inside diameter: 51.015 to 51.040 mm (2.0085 to 2.0095 inch)
Maximum inside diameter: 51.040 mm (2.0095 inch)
If the inside diameter exceeds the maximum, replace the 4th gear.

5. INSPECT NO.2 TRANSMISSION HUB SLEEVE

a) Check the sliding condition between the No.2 transmission clutch hub and No.2 transmission hub sleeve.
b) Check that the spline gear teeth of the No.2 transmission hub sleeve are not worn.
If there are any defects, replace the No.2 transmission hub sleeve.

c) Using vernier calipers, measure the width of the No.2 transmission hub sleeve groove (A) and the thickness of the claw part on the No.2 gear shift forks (B), and calculate the clearance.
Standard clearance (A - B): 0.28 to 0.66 mm (0.0110 to 0.0260 inch)
If the clearance is outside the specification, replace the No.2 transmission hub sleeve and gear shift fork.

6. INSPECT NO.3 TRANSMISSION HUB SLEEVE

a) Check the sliding condition between the No.3 transmission clutch hub and No.3 transmission hub sleeve.
b) Check that the spline gear teeth of the No.3 transmission hub sleeve are not worn.
If there are any defects, replace the No.3 transmission hub sleeve.

c) Using vernier calipers, measure the width of the No.2 transmission hub sleeve groove (A) and the thickness of the claw part on the No.3 and No.3 gear shift forks (B), and calculate the clearance.
Standard clearance (A - B): 0.28 to 0.66 mm (0.0110 to 0.0260 inch)
If the clearance is outside the specification, replace the No.3 transmission hub sleeve and gear shift fork.

7. INSPECT NO.3 SYNCHRONIZER RING (for 6th Gear)

a) Using a feeler gauge, measure the clearance between the synchronizer ring and the 6th gear.
Standard clearance: 0.80 to 1.60 mm (0.0315 to 0.0630 inch)
Minimum clearance: 0.80 mm (0.0315 inch)
If the clearance is less than the minimum, replace the synchronizer ring.

b) Coat the 6th gear cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it onto the 6th gear cone. Check that the ring locks.