Part 2
INPUT SHAFT Continued8. INSPECT NO.2 SYNCHRONIZER RING SET
a) Using a feeler gauge, measure the clearance between the synchronizer ring and the 3rd gear.
Standard clearance:
Inner: 1.20 to 2.20 mm (0.0472 to 0.0866 inch)
Middle: 0.60 to 1.80 mm (0.0236 to 0.0709 inch)
Outer: 0.80 to 1.80 mm (0.0315 to 0.0709 inch)
Minimum clearance:
Inner: 1.20 mm (0.0472 inch)
Middle: 0.60 mm (0.0236 inch)
Outer: 0.80 mm (0.0315 inch)
If the clearance is less than the minimum, replace the synchronizer ring.
b) Coat the 3rd 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 3rd gear cone. Check that the ring locks.
9. INSPECT NO.3 SYNCHRONIZER RING (for 4th Gear)
a) Using a feeler gauge, measure the clearance between the synchronizer ring and 4th 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 4th 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 4th gear cone. Check that the ring locks.
10. INSPECT 3RD GEAR THRUST WASHER
a) Using a micrometer, measure the thrust washer thickness.
Standard thickness: 7.12 to 7.18 mm (0.2803 to 0.2827 inch)
Minimum thickness: 7.12 mm (0.2803 inch)
If the thickness is less than the minimum, replace the thrust washer.
REASSEMBLY
1. INSTALL INPUT SHAFT FRONT BEARING
a) Using SST and a press, install the input shaft front bearing onto the input shaft.
SST 09950-00020
HINT: Make sure that the groove of the bearing faces the correct direction as shown in the illustration.
2. INSTALL INPUT SHAFT FRONT BEARING SNAP RING
a) Select a snap ring that will allow minimum axial play.
Standard clearance: 0.1 mm (0.004 inch) or less
Snap Ring Thickness:
b) Using a brass bar and hammer, install the snap ring onto the input shaft.
3. INSTALL NO.2 TRANSMISSION CLUTCH HUB
a) Apply a light coat of gear oil to the sleeve and hub.
b) Install the clutch hub sleeve onto the No.2 transmission clutch hub.
c) Install the 3 shifting keys, 3 shifting key springs and 3 balls onto the clutch hub.
NOTICE: Take care to prevent the ball from flying off.
HINT: Make sure that the No.2 transmission clutch hub faces the correct direction as shown in the illustration.
4. INSTALL NO.3 TRANSMISSION CLUTCH HUB
a) Apply a light coat of gear oil to the sleeve and hub.
b) Install the clutch hub sleeve onto the No.3 transmission clutch hub.
c) Install the 3 shifting keys, 3 shifting key springs and 3 balls onto the clutch hub.
NOTICE: Take care to prevent the ball from flying off.
HINT: Make sure that the No.2 transmission clutch hub faces the correct direction as shown in the illustration.
5. INSTALL 4TH GEAR NEEDLE ROLLER BEARING
a) Coat the 4th gear needle roller bearing with gear oil, then install it onto the input shaft.
6. INSTALL 4TH GEAR
a) Coat the 4th gear and No.3 synchronizer ring with gear oil, then install them onto the input shaft.
b) Using SST and a press, install the No.2 transmission clutch hub onto the input shaft.
SST 09308-14010
HINT: Align the convex portion of the synchronizer ring with the groove of the clutch hub.
c) Install the clutch hub and confirm that the gear and synchronizer ring move smoothly.
7. INSTALL NO.2 CLUTCH HUB SETTING SHAFT SNAP RING
a) Select a snap ring that will allow minimum axial play.
Standard clearance: 0.1 mm (0.004 inch) or less
Snap Ring Thickness (part 1):
Snap Ring Thickness (part 2):
b) Using a snap ring expander, install the snap ring onto the input shaft.
8. INSTALL NO.2 SYNCHRONIZER RING SET
a) Coat the No.2 synchronizer ring set with gear oil, then install it onto the input shaft.
9. INSTALL SPACER
a) Coat the spacer with gear oil, and install it onto the input shaft.
10. INSTALL 3RD GEAR NEEDLE ROLLER BEARING
a) Coat the 3rd gear needle roller bearing with gear oil, and install it onto the input shaft.
11. INSTALL STRAIGHT PIN
a) Install the straight pin onto the input shaft.
12. INSTALL 3RD GEAR
a) Coat the 3rd gear with gear oil, and install it onto the input shaft.
13. INSTALL 3RD GEAR THRUST WASHER
a) Coat the 3rd gear thrust washer with gear oil, and install it onto the input shaft.
HINT: Align the straight pin with the groove of the gear thrust washer and install it.
14. INSTALL GEAR THRUST WASHER SHAFT SNAP RING
a) Select a snap ring that will allow minimum axial play.
Standard clearance: 0.1 mm (0.004 inch) or less
Snap Ring Thickness:
b) Using a snap ring expander, install the snap ring onto the input shaft.
15. INSTALL SPACER
a) Coat the spacer with gear oil, and install it onto the input shaft.
16. INSTALL 6TH GEAR NEEDLE ROLLER BEARING
a) Coat the 6th gear needle roller bearing with gear oil, and install it onto the input shaft.
17. INSTALL 6TH GEAR
a) Install the 6th gear onto the input shaft.
b) Install the synchronizer ring onto the input shaft.
c) Using SST and a press, install the clutch hub onto the input shaft.
SST 09309-37010, 09950-00020
d) Install the clutch hub and confirm that the gear and synchronizer ring move smoothly.
18. INSTALL TRANSMISSION CLUTCH HUB NO.3 SHAFT SNAP RING
a) Select a snap ring that will allow minimum axial play.
Standard clearance: 0.1 mm (0.004 inch) or less
Snap Ring Thickness (part 1):
Snap Ring Thickness (part 2):
b) Using a brass bar and a hammer, install the snap ring onto the input shaft.
19. 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.
20. 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.
21. INSPECT 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.
22. 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.
23. 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.
24. 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.