Intermediate Gear Assembly

DISASSEMBLY AND REASSEMBLY

SERVICE POINTS OF DISASSEMBLY




2. REMOVAL OF TAPER ROLLER BEARING/4. 1ST SPEED GEAR
Using the special tool, remove the taper roller bearing, the 1st speed gear, and the bearing sleeve.

CAUTION:
1. Do not reuse the bearing if it has been removed from the shaft.
2. Replace the inner and outer races of the taper roller bearing as a set.




10. REMOVAL OF 1ST-2ND SPEED SYNCHRONIZER HUB/12. 2ND SPEED GEAR
Using the special tool, remove the 1st-2nd speed synchronizer assembly and 2nd speed gear.




14. REMOVAL OF TAPER ROLLER BEARING
Using the special tool, remove the taper roller bearing.

CAUTION:
1. Do not reuse the bearing if it has been removed from the shaft.
2. Replace the inner and outer races of the taper roller bearing as a set.

INSPECTION




INTERMEDIATE GEAR
- Check the outer surface of the intermediate gear where the needle bearing is mounted for damage, abnormal wear, and seizure (portion (A)).
- Check splines for damage and wear.




NEEDLE BEARING
- Mate the needle bearing with the shaft or bearing sleeve and gear, and check to see if rotation is smooth with no binding, noise, or play.
- Check the needle bearing cage for possible deformation.




SYNCHRONIZER RING
- Check the clutch gear teeth for damage and breakage.
- Check the cone inside paper lining for damage, wear or peeling.




- Force the synchronizer ring toward the clutch gear and check clearance "A". Replace if the measurement is below the limit.

Limit: 0.5 mm (.020 in.)




SYNCHRONIZER SLEEVE AND HUB
- Mate the synchronizer sleeve with the hub and check to see if they slide smoothly.
- Check to see if the sleeve is free from damage at its inside front and rear ends.
- Check the hub front and rear end faces (in contact with each speed gear) for wear.

CAUTION: When replacement is necessary, replace the synchronizer hub and sleeve as a set.




SYNCHRONIZER KEY AND SPRING
- Check the synchronizer key center protrusion for wear.
- Check the spring for proper tension, possible deformation and breakage.




SPEED GEARS
- Check the bevel and clutch gear teeth for damage and wear.
- Check the synchronizer cone for rough surface, damage, and wear.
- Check the gear bore and front and rear ends for damage and wear.

SERVICE POINTS OF REASSEMBLY




14. INSTALLATION OF TAPER ROLLER BEARING
Using the special tool, press-fit the taper roller bearing over the intermediate gear.

CAUTION: Apply pressure with the special tool only to the inner race when installing the bearing.




11./6. INSTALLATION OF SYNCHRONIZER RING
Note the identification mark made on the 1st speed synchronizer ring.




10. INSTALLATION OF 1ST-2ND SYNCHRONIZER HUB / 9. SYNCHRONIZER KEY / 8. 1ST-2ND SYNCHRONIZER SLEEVE / 7. SYNCHRONIZER SPRING
1. Mate the 1st-2nd speed synchronizer hub and sleeve as shown.




2. Install the synchronizer spring so that its protrusion fits into the groove in synchronizer key.

CAUTION: Make sure that the protrusions in the front and rear springs are not in the groove of the same key.

NOTE: A synchronizer spring different from the one shown in the figure may be used but the explanation is the same.




3. Using the special tool, press-fit the 1st-2nd speed synchronizer assembly over the intermediate gear.

CAUTION:
1. When installing the synchronizer assembly, make sure that the three synchronizer keys are seated correctly in their respective grooves in the synchronizer ring.
2. After installing the synchronizer assembly, check to see if the 3rd speed gear rotates smoothly.




3. INSTALLATION OF BEARING SLEEVE
Using the special tool, press-fit the 1st speed gear and bearing sleeve.




2. INSTALLATION OF TAPER ROLLER BEARING
Using the special tool, press-fit the taper roller bearing

CAUTION: Apply pressure with the special tool only to the inner race when installing the bearing.




1. INSTALLATION OF SNAP RING
Select and install the snap ring so that the end play of the intermediate shaft is up to specification.

Standard value: 0.01 - 0.11 mm (.0004 - .0043 in.)