Part 1

MAJOR OVERHAUL





CASE COMPONENTS





GEAR COMPONENTS





SHIFT CONTROL COMPONENTS

DISASSEMBLY





1. Remove transmission case while slightly tilting it to prevent 5th shift fork from interfering with case.





2. Draw out reverse idler spacer and fork shaft, then remove 5th and 3rd & 4th shift forks.
- Be careful not to lose shifter cap.





3. Remove control bracket with 1st & 2nd shift fork.
- Be careful not to lose shifter cap.





4. Remove gear components from clutch housing.
a. Remove mainshaft and final drive assembly.
- Always withdraw mainshaft straight out. Failure to do so can damage resin oil channel on clutch housing side.





b. Remove bearing retainer securing bolts.





c. Remove input shaft together with bearing retainer and reverse idler gear by tapping lightly.
- Do not draw out reverse idler shaft from clutch housing because these fittings will be loose.
- Be careful not to scratch oil seal lip with shaft spline when removing input shaft.





5. Remove oil pocket, shift check ball, shift check spring and check ball plug.





6. Drive retaining pin out of striking lever, then remove striking rod, striking lever and striking interlock.
- Select a position where retaining pin does not interfere with clutch housing when removing retaining pin.





- Be careful not to damage oil seal lip, when removing striking rod. If necessary, tape edges of striking rod.





7. Remove reverse check plug, then detach reverse check spring and check balls.
8. Remove check sleeve assembly.

REPAIR FOR COMPONENT PARTS
INPUT SHAFT AND GEARS
DISASSEMBLY





1. Before disassembly, check 5th input gear end play.

Gear end play: 0.18 - 0.31 Nm (0.0071 - 0.0122 inch)

- If not within specification, disassemble and check contact surface of gear, shaft and hub. Then check clearance of snap ring groove.





2. Remove snap ring and 5th stopper.
3. Remove 5th synchronizer, 5th input gear and 5th gear needle bearing.





4. Remove snap ring of input shaft front bearing and spacer.
5. Pull out input shaft front bearing.
6. Remove bearing retainer.

INSPECTION
Gear and Shaft





- Check shaft for cracks, wear or bending.
- Check gears for excessive wear, chips or cracks.

Synchronizer





- 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.





- Measure clearance between baulk ring and gear.

Clearance between baulk ring and gear:
Standard: 1.0 - 1.35 Nm (0.0394 - 0.0531 inch)
Wear limit: 0.7 Nm (0.028 inch)

Bearing





- Make sure bearings roll freely and are free from noise, cracks, pitting or wear.

ASSEMBLY





1. Assemble 5th synchronizer.





- Be careful not to hook front and rear ends of spread spring to the same insert.





2. Install bearing retainer.
3. Press on input shaft front bearing.
4. Install spacer.





5. Select and install snap ring that gives the proper clearance of groove in input shaft.

Allowable clearance of groove: 0 - 0.1 Nm (0 - 0.004 inch)

Snap ring of input shaft front bearing: Refer to image.





6. Install 5th gear needle bearing, 5th input gear, 5th synchronizer and 5th stopper with Tool.
7. Measure gear end play as the final check.





8. Select and install snap ring that gives the proper clearance of groove in input shaft.

Allowable clearance of groove: 0 - 0.1 Nm (0 - 0.004 inch)

Snap ring of 5th synchronizer: Refer to image.

MAINSHAFT AND GEARS
DISASSEMBLY





1. Before disassembly, measure gear end plays.

Gear end play:
1st main gear: 0.18 - 0.31 Nm (0.0071 - 0.0122 inch)
2nd, 3rd, 4th main gear: 0.20 - 0.30 Nm (0.0079 - 0.0118 inch)

- If end play is not within the specified limit, disassemble and check the parts.





2. Press out mainshaft front and rear bearing.





3. Remove C-ring holder, mainshaft C-rings and thrust washer.





4. Press out 5th main gear.





5. Remove 4th main gear, 4th bushing and steel ball.
- Be careful not to lose steel ball.





6. Remove 3rd & 4th synchronizer, 3rd main gear, 2nd & 3rd bushing, steel ball and 2nd main gear.
- Be careful not to lose steel ball.





7. Remove 1st & 2nd synchronizer and 1st main gear, then remove 1st gear needle bearing.

INSPECTION
Gear and Shaft





- Check shaft for cracks, wear or bending.
- Check gears for excessive wear, chips or cracks.

Synchronizer





- Check spline portion of coupling sleeves, hubs and gears for wear or cracks.
- Check baulk rings for cracks or deformation.
- Check insert springs for wear or deformation.





- Measure clearance between baulk ring and gear.

Clearance between baulk rings and 1st through 5th main gears:
Standard: 1.0 - 1.35 Nm (0.0394 - 0.0531 inch)
Wear limit: 0.7 Nm (0.028 inch)

Bearing





- Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
- When replacing tapered roller bearing, replace outer and inner race as a set.

ASSEMBLY





1. Assemble 1st & 2nd and 3rd & 4th synchronizers.





- Be careful not to hook front and rear ends of spread spring to the same insert.





2. Install 1st gear needle bearing and 1st main gear.
3. Press on 1st & 2nd synchronizer.





4. Install steel ball, 2nd main gear, 2nd & 3rd bushing, 3rd main gear and 3rd & 4th synchronizer.
- Apply multi-purpose grease to steel ball before installing it.
- 2nd & 3rd bushing has a groove in which steel ball fits.





5. Install steel ball, 4th bushing and 4th main gear.
- Apply multi-purpose grease to steel ball before installing it.
- 4th bushing has a groove in which steel ball fits.





6. Press on 5th main gear.





7. Install thrust washer.
8. Select and install mainshaft C-ring that gives proper clearance of groove in mainshaft.

Allowable clearance of groove: 0 - 0.1 Nm (0 - 0.004 inch)

Mainshaft C-ring: Refer to image.

9. Install C-ring holder.