Part 1
CASE COMPONENTS
GEAR COMPONENTS
SHIFT CONTROL COMPONENTS
CASE COMPONENTS
DISASSEMBLY
1. Remove check ball plug, check spring and check ball. Then remove interlock stopper.
- If interlock assembly is removed as a unit, the check ball can fall into transmission case.
- Be careful not to lose check ball.
2. Remove control housing, return spring and check ball.
- Be careful not to lose check ball.
3. Drive out retaining pin from striking arm.
4. Remove rear extension (or OD gear case) together with striking arm by tapping lightly.
5. Remove front cover and gasket.
6. Remove stopper ring and main drive bearing snap ring.
7. Remove transmission case by tapping lightly.
8. Remove front cover oil seal.
SHIFT CONTROL COMPONENTS
DISASSEMBLY
1. Mount adapter plate on vise.
2. Remove OD & reverse fork rod.
3. Drive out retaining pin from striking lever.
4. While pulling out striking rod, remove striking lever and striking interlock. Then remove 1st & 2nd, 3rd & 4th and reverse shift fork.
5. Drive out retaining pin from OD shift fork.
6. Pull out OD fork rod and then remove OD shift fork.
GEAR COMPONENTS
DISASSEMBLY
1. Before removing gears and shafts, measure each gear end play.
Gear end play: Refer to image.
- If not within specification, disassemble and check contact surface of gear to hub, washer, bushing, needle bearing and shaft.
2. Remove rear side components on mainshaft and counter gear.
a. Remove reverse coupling sleeve.
b. Remove mainshaft rear snap ring and counter gear rear snap ring.
c. Remove C-ring holder and mainshaft C-rings from mainshaft. Use punch and hammer to remove C-rings.
d. Pull out counter gear rear end bearing.
e. Remove reverse idler gear and reverse idler thrust washers.
f. Pull out mainshaft rear bearing (2WD model).
g. Pull out reverse main gear together with mainshaft spacer and reverse synchronizer hub. Then remove reverse gear needle bearings.
h. Pull out reverse counter gear.
i. Remove OD coupling sleeve together with OD baulk ring, reverse baulk ring and spring inserts.
j. Pull out reverse gear bushing.
k. Pull out OD counter gear together with reverse cone.
3. Press out mainshaft and counter gear alternately.
4. Remove front side components on mainshaft.
a. Remove 1st gear washer and steel ball.
b. Remove 1st main gear and 1st gear needle bearing.
- Be careful not to lose steel ball.
c. Press out 2nd main gear together with 1st gear bushing and 1st & 2nd synchronizer assembly.
d. Remove mainshaft front snap ring.
e. Press out 3rd main gear together with 3rd & 4th synchronizer assembly and 3rd gear needle bearing.
5. Remove front side components on counter gear.
a. Remove counter gear rear thrust bearing.
b. Remove sub-gear components.
6. Remove main drive gear bearing.
a. Remove main drive gear snap ring.
b. Press out main drive gear bearing.
7. Remove bearings from case components.
SHIFT CONTROL COMPONENTS
INSPECTION
- Check contact surface and sliding surface for wear, scratches, projections or other damage.
GEAR COMPONENTS
INSPECTION
Gears and Shafts
- Check shafts for cracks, wear or bending.
- Check gears for excessive wear, chips or cracks.
Synchronizers
- Check spline portion of coupling sleeves, hubs, and gears for wear or cracks.
- Check baulk rings for cracks or deformation.
- Check shifting inserts for wear or deformation.
- Check insert springs for deformation.
- Measure wear of main drive, 1st and OD baulk rings.
Clearance between baulk ring and gear: Refer to image.
- If the clearance is smaller than the wear limit, replace baulk ring.
- Measure wear of 2nd and 3rd baulk rings.
a. Place baulk rings in position on synchronizer cone.
b. While holding baulk rings against synchronizer cone as far as it will go, measure dimensions "A" and "B".
Standard:
A 0.7 - 0.9 mm (0.028 - 0.035 inch)
B 0.6 - 1.1 mm (0.024 - 0.043 inch)
Wear limit: 0.2 mm (0.008 inch)
- If dimension "A" or "B" is smaller than the wear limit, replace outer baulk ring, inner baulk ring and synchronizer cone as a set.