Disassembly Service Points
DISASSEMBLY SERVICE POINTSA. BALL BEARING / TAPER ROLLER BEARING / 1ST SPEED GEAR REMOVAL
CAUTION: Do not reuse the bearing removed from the shaft.
CAUTION:
- Do not reuse the bearing removed from the shaft.
- Replace the inner and outer races of the taper roller bearing as a set.
B. 1ST-2ND SPEED SYNCHRONIZER HUB / 2ND SPEED GEAR REMOVAL
C. BALL BEARING REMOVAL
CAUTION: Do not reuse the bearing removed from the shaft.
D. TAPER ROLLER BEARING REMOVAL
CAUTION:
- Do not reuse the bearing removed from the shaft.
- Replace the inner and outer races of the taper roller bearing as a set.
INSPECTION
INTERMEDIATE GEAR
(1) Check the outer surface of the intermediate gear 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 (.02 in.)
SYNCHRONIZER OUTER RING, INNER RING AND CONE
(1) Check that there are no scratches or damage on the clutch gear teeth and cone surface.
(2) Check that there are no scratches, wear or peeling on the paper lining surface.
(3) Install the outer ring, inner ring and cone, and press them onto the clutch gear. Check clearance "A", and replace if "A" is below the limit value.
Limit: 0.5 mm (.02 in.)
CAUTION: Replace the outer ring, inner ring and cone as a set.
SYNCHRONIZER SLEEVE AND HUB
(1) Combine the synchronizer sleeve and hub and check that they slide smoothly.
(2) Check that the sleeve is free from damage at its inside front and rear ends.
(3) Check for wear of the hub end surface (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 bevel gear and clutch gear teeth for damage and wear.
(2) Check the synchronizer cone for rough surface, damage and wear.
(3) Check the gear bore and front and rear ends for damage and wear.
REASSEMBLY SERVICE POINTS
A. BALL BEARING INSTALLATION
B. TAPER ROLLER BEARING INSTALLATION
CAUTION: When installing the bearing, push the inner race only.
C. SYNCHRONIZER RINGS FOR 1ST SPEED GEAR, 2ND SPEED GEAR INSTALLATION
(1) The 1st speed gear and 2nd speed gear of synchronizer rings have an identification mark.
D. 1ST-2ND SPEED SYNCHRONIZER HUB / SYNCHRONIZER KEY / 1ST-2ND SYNCHRONIZER SLEEVE INSTALLATION
(1) Combine the 1st-2nd speed synchronizer hub and sleeve as illustrated.
(2) The synchronizer sleeve has tooth missing at six portions. Assemble the hub to the sleeve in such a way that the center tooth "T" between two missing teeth will touch the synchronizer key.
E. SYNCHRONIZER SPRING INSTALLATION
(1) When installing the synchronizer springs, be sure to position each spring with respect to the keys as illustrated.
F. BEARING SLEEVE INSTALLATION
G. TAPER ROLLER BEARING INSTALLATION
CAUTION: When installing the bearing, push the inner race only.
H. BALL BEARING INSTALLATION
I. SNAP RING INSTALLATION
(1) Select and install the snap ring that gives standard intermediate gear bearing end play.
Standard value:
Intermediate gear bearing end play:
0.01-0.11 mm (.0004 - .0043 in.) (F5M31,W5M31)
0.01- 0.14 mm (.0004 - .0055 in.) (F4M21, F5M21, F5M22, F5M33, W5M33)