Disassembly Service Points

DISASSEMBLY SERVICE POINTS








A. FRONT BALL BEARING / FRONT TAPER ROLLER BEARING REMOVAL





B. BEARING SLEEVE FOR 5TH SPEED GEAR REMOVAL





C. 4TH SPEED GEAR / 3RD SPEED GEAR REMOVAL








D. REAR BALL BEARING/TAPER ROLLER BEARING/ 3RD SPEED GEAR REMOVAL

INSPECTION

INPUT SHAFT





(1) Check the outer surface of the input shaft where the needle bearing is mounted for damage, abnormal wear and seizure [portion A].
(2) Check the splines for damage and wear.

NEEDLE BEARING





(1) Combine the needle bearing with the shaft or bearing sleeve and gear and check that it rotates smoothly without abnormal noise or play.
(2) Check the needle bearing cage for deformation.

SYNCHRONIZER RING





(1) Check the clutch gear teeth for damage and breakage.
(2) Check the internal surface for damage, wear and broken threads.





(3) Force the synchronizer ring toward the clutch gear and check clearance "A". Replace if it is out of specification.

Limit: 0.5 mm (0.02 in.)

SYNCHRONIZER SLEEVE AND HUB





(1) Combine the synchronizer sleeve and hub and check that they slide smoothly.
(2) Check that the sleeve is tree from damage at its inside front and rear ends.
(3) Check for wear of the hub end surfaces (in contact with each speed gear).

CAUTION: When replacing, replace the synchronizer hub and sleeve as a set.

SYNCHRONIZER KEY AND SPRING





(1) Check for wear of the synchronizer key center protrusion.
(2) Check the spring for weakness, deformation and breakage.

SPEED GEARS





(1) Check the synchronizer cone for rough surface, damage and wear.
(2) Check the gear bore and front and rear ends for damage and wear.

REASSEMBLY SERVICE POINTS





A. 3RD-4TH SPEED SYNCHRONIZER HUB / 3RD-4TH SPEED SYNCHRONIZER SLEEVE INSTALLATION

B. SYNCHRONIZER SPRING / SYNCHRONIZER KEY INSTALLATION





(1) When installing the synchronizer springs, be sure to position each spring with respect to the keys as illustrated.







C. BEARING SLEEVE FOR 4TH SPEED GEAR INSTALLATION





D. SUB GEAR / CONE SPRING / SNAP RING INSTALLATION


E. SPACER INSTALLATION





(1) Install with the side having the identification mark "1" on the 4th speed gear side. Spacers without identification mark may be installed in either direction.





F. INNER RING FOR REAR BEARING INSTALLATION








G. REAR BALL BEARING INSTALLATION

H. SNAP RING INSTALLATION





(1) Select the thickest snap ring that can be fitted in the snap ring groove.

Standard value:
Input shaft rear bearing end play
0 -0.09 mm (0 - .0035 in.)

CAUTION:
- Do not reuse the snap ring.
- The snap ring may be opened too wide by pliers, resulting in improper installation of the sleeve.

I. BEARING SLEEVE FOR 5TH SPEED GEAR INSTALLATION

CAUTION: When press-fitting the sleeve to the input shaft, make sure that the sleeve flange is closely fitted to the bearing.








J. FRONT BALL BEARING / FRONT TAPER ROLLER BEARING INSTALLATION

K. SNAP RING INSTALLATION





(1) Snap rings are available in three different thickness. Select the thickest one that fits in the snap ring groove.

Standard value:
Input shaft front bearing end play
0.1 -0.12 mm (.0004 - .0047 in.)

CAUTION: Do not damage the input shaft oil seal contacting portion.