Gear Components

GEAR COMPONENTS / FS5R30A - Manual Trans.:

GEAR COMPONENTS / Disassembly

1. Before removing gears and shafts, measure each gear end play.
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. Remove counter gear rear end bearing using a puller.
e. Remove reverse idler thrust washer and reverse idler gear (VG33E model) or snap ring, sub-gear bracket, steel ball, subgear spring, sub-gear and reverse idler (VG33ER model) and reverse idler needle bearings.
f. Remove mainshaft rear bearing (2WD model) using Tools.

Tool number:.......................J-26349-A, J-25726-B

g. Remove mainshaft spacer.

h. Remove reverse main gear together with mainshaft spacer and reverse synchronizer hub using a puller. Then remove reverse gear needle bearings.

i. Remove reverse counter gear using a puller.
j. Remove OD coupling sleeve together with OD baulk ring, reverse baulk ring and spring inserts.

k. Remove reverse gear bushing using a puller.
l. Remove speedometer drive gear (2WD model).

m. Remove OD gear bushing, OD gear needle bearing, OD counter gear and reverse cone using puller.

3. Press out mainshaft and counter gear alternately using Tool.

Tool number:..........................ST33230000 (-)

4. Remove front side components on mainshaft.

a. Remove 1st gear washer and steel ball.
Be careful not to lose steel ball.

b. Remove 1st main gear and 1st gear needle bearing.

c. Press out 2nd main gear together with 1st gear bushing, 2nd gear needle bearing and 1st and 2nd synchronizer assembly using Tool.

Tool number:....................ST30031000 (J22912-01)

d. Remove mainshaft front bearing snap ring.

e. Press out 3rd main gear together with 3rd and 4th synchronizer assembly and 3rd gear needle bearing.

5. Remove front side components on counter gear.

a. Remove counter gear rear thrust bearing using Tool.

Tool number:..............................ST30031000 (J22912-01)

b. Remove sub-gear snap ring, sub-gear bracket, sub-gear spring, sub-gear and steel ball.

6. Remove main drive gear bearing.
a. Remove main drive gear snap ring.
b. Press out main drive gear bearing using Tool.

Tool number:...............................ST30031000 (J22912-01)

c. Remove pilot bearing.

7. Remove front bearing snap ring from adapter plate.

8. Remove bearings from case components using Tool.

Tool Numbers:
Counter gear front bearing:............................ST22350000 (J25678-01), KV38100300 (J25523)
Mainshaft front bearing:................................ST30720000 (J34331)
Mainshaft rear bearing:.................................ST37750000 (J34332)
Counter gear rear bearing:..............................ST37750000 (J34286)

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.

Clearance Between Single Baulk Ring and Gear / FS5R30A - Manual Trans.:

Measure wear of main drive, 1st (VG33E model) and OD baulk rings.
If the clearance is smaller than the wear limit, replace baulk ring.

Measure wear of 1st, 2nd and 3rd double baulk rings.

1st, 2nd and 3rd double baulk rings: VG33ER model.
2nd and 3rd double baulk rings: VG33E model.

Place baulk rings in position on synchronizer cone.
While holding baulk rings against synchronizer cone as far as it will go, measure dimensions "A" and "B".

Standard
Dimension "A" :..........................0.7 - 0.9 mm (0.028 - 0.035 inch)
Dimension "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.

Measure wear of reverse baulk ring.
Place baulk ring in position on reverse cone.
While holding baulk ring against reverse cone as far as it will go, measure dimension "A" with dial indicator.

Standard
Dimension "A" :...................................0.35 to 0.95 mm (0.0119 to 0.0295 inch)
Wear limit :...............................................1.1 mm (0.043 inch)

If dimension "A" is larger than the wear limit, replace baulk ring.

BEARINGS
Make sure bearings roll freely and are free from noise, crack, pitting or wear.

GEAR COMPONENTS / Assembly
1. Install bearings into case components.

Tool Numbers
Counter gear front bearing:..................................ST33210000 (J25523)
Mainshaft front bearing:.....................................ST30720000 (J34331)
Mainshaft rear bearing:......................................ST33220000 (J25804-01)
Counter gear rear bearing:...................................KV38100300( J25523)

2. Install mainshaft front bearing snap ring into adapter plate.
3. Install bearing retainer.

Bearing retainer bolt.............................16 - 20 Nm (1.6 - 2.1 kgf-cm, 12 - 15 ft. lbs.)

4. Install main drive gear bearing.

a. Press main drive gear bearing using Tool.

Tool number:...........................ST30613000 (J25742-3)

b. Install pilot bearing.

c. Select proper main drive gear snap ring to minimize clearance of groove.

Main drive gear............................0 - 0.1 mm (0 - 0.003 inch) snap ring groove allowable clearance

d. Install selected main drive gear snap ring on main drive gear.
5. Install components on counter gear.

a. Install sub-gear, sub-gear spring, sub-gear bracket and sub-gear snap ring.
When installing sub-gear snap ring, tap sub-gear snap ring into position on counter gear using Tool.

Tool number:.............................J26092

b. Install counter gear rear thrust bearing using a brass drift.
6. Install front side components on mainshaft.

a. Assemble 1st and 2nd synchronizer.

b. Assemble 3rd and 4th synchronizer.

c. Press on 3rd and 4th synchronizer assembly together with 3rd main gear and 3rd gear needle bearing.
Pay attention to direction of synchronizer assembly.

d. Select proper mainshaft front bearing snap ring to minimize clearance of groove.

Mainshaft front bearing snap ring groove allowable clearance:......................0 - 0.1 mm (0 - 0.003 inch)

e. Install selected mainshaft front bearing snap ring on mainshaft.

f. Press on 1st and 2nd synchronizer assembly together with 2nd main gear and 2nd gear needle bearing.

g. Press on 1st gear bushing using 1st gear washer.

h. Install 1st main gear and 1st gear needle bearing.
i. Install steel ball and 1st gear washer.
Apply multi-purpose grease to steel ball and 1st gear washer before installing.

7. Select proper counter gear front bearing shim when replacing transmission case, counter gear, counter gear rear thrust bearing or sub-gear components.

a. Install counter gear with sub-gear components, counter gear front thrust washer and counter gear rear thrust washer on adapter plate.
b. Remove counter gear front bearing shim from transmission case.
c. Place adapter plate and counter gear assembly in transmission case (case inverted).

d. Tighten adapter plate to transmission case using 2 bolts.
e. Place dial indicator on rear end of counter gear.
f. Move counter gear up and down and measure dial indicator deflection.
g. Select proper thrust washer using the table as a guide.

Counter gear end play................................0.10 - 0.26 mm (0.0040 - 0.0102 inch)

h. Separate adapter plate and transmission case.
i. Remove counter gear assembly.

8. Select proper reverse idler rear thrust washer when replacing rear extension (or OD gear case), reverse idler gear, reverse idler shaft or reverse idler front thrust washer.

a. Install reverse idler gear, reverse idler needle bearings, reverse idler rear thrust washer and reverse idler shaft into rear extension (or OD gear case).
When replacing reverse idler rear thrust washer, install either A or B.

b. Place dial indicator on front end of reverse idler shaft.
c. Put straightedge on front surface of rear extension (or O/D gear case) as a stopper of reverse idler shaft.
d. Move reverse idler shaft up and down and measure reverse idler gear end play.

Reverse idler gear:...............................0.30 - 0.53 mm (0.0119 - 0.0208 inch) end play

e. If not within specification, replace reverse idler rear thrust washer with the other (A or B) and check again.

9. Install mainshaft and counter gear on adapter plate and main drive gear on mainshaft.

a. Mount adapter plate on vise and apply multi-purpose grease to counter gear rear bearing.

b. Partially install mainshaft on mainshaft front bearing.
To allow for installation of counter gear, do not install mainshaft completely.

c. Install counter gear in counter gear rear bearing and install main drive gear, pilot bearing and spacer on mainshaft.

When installing counter gear into counter gear rear bearing, push up on upper roller of counter gear rear bearing with screwdriver.

d. Install Tools (J26349-3) onto adapter plate and C-ring and C-ring holder on mainshaft.
e. Install Tool (J34328) on mainshaft.

f. Install mainshaft and counter gear completely by extending length of Tool (J26349-3).

10. Install rear side components on mainshaft and counter gear.

a. Install OD gear bushing using Tool while pushing on the front of counter gear.

Tool number:.....................................ST37750000 (J34332)

b. Install OD main gear using Tool.
Pay attention to direction of OD main gear. (B is wider than A as shown.)

Tool number:........................J34342

c. Install adapter plate with gear assembly onto transmission case.
d. Install OD gear needle bearing and then install OD counter gear and reverse idler shaft.

e. Install reverse gear bushing with speedometer drive gear (2WD model) using Tool.

Tool number:........................J34342

f. Install reverse cone using Tool.

Tool number:.......................................ST37750000 (J34332)

g. Install insert springs and reverse baulk ring on OD coupling sleeve. Then install them and OD baulk ring on OD counter gear.
Pay attention to direction of OD coupling sleeve.

h. Install reverse counter gear using Tool.

Tool number:..........................................ST37750000 (J34332)

i. Install reverse gear needle bearing and then install reverse main gear, reverse idler gear and reverse idler rear thrust washer.

j. Install reverse synchronizer hub using Tool.
Pay attention to its direction.

k. Install mainshaft spacer and mainshaft rear bearing (2WID model) using Tool.

Tool number:................................J-26349-A, J-25726-B

l. Install counter gear rear end bearing using Tool.

Tool number:.....................................ST37750000 (J25679-01)

m. Separate adapter plate from transmission case and mount adapter plate on vise again.

n. Select proper mainshaft C-ring to minimize clearance of groove.

Mainshaft C-ring groove allowable clearance:................................0 - 0.1 mm (0 - 0.003 inch)

o. Install selected mainshaft C-ring, C-ring holder and mainshaft rear snap ring.

p. Select proper counter gear rear snap ring to minimize clearance of groove.

Counter gear rear snap ring groove allowable clearance..........................0 - 0.1 mm (0 - 0.003 inch)

q. Install selected counter gear rear snap ring.

r. Install reverse coupling sleeve.
Pay attention to its direction.

s. Measure each gear end play as a final check.