Repair For Component Parts
INPUT SHAFT AND GEARSDISASSEMBLY
1. Before disassembly, check 3rd, 4th and 5th input gear end plays.
Gear end play: Refer to Specifications. Mechanical Specifications
^ If not within specification, disassemble and check contact surface of gear, shaft and hub. Check clearance of snap ring groove. Refer to "ASSEMBLY"
2. Remove input shaft rear bearing with Tool.
3. Remove 5th & reverse synchronizer and 5th input gear with Tool.
4. Remove thrust washer ring, thrust washers and 4th input gear.
5. Remove snap ring.
6. Remove 3rd & 4th synchronizer and 3rd input gear with Tool.
7. Remove input shaft front bearing with Tool.
INSPECTION
Gear and shaft
^ Check shaft for cracks, wear and bending.
^ Check gears for excessive wear, chips and cracks.
Synchronizer
^ Check spline portion of coupling sleeves, hubs and gears for wear or cracks.
^ Check baulk rings for cracks and deformation.
^ Check insert springs for wear and deformation.
^ Measure clearance between baulk ring and gear (3rd, 4th and 5th).
Clearance between baulk ring and gear: Refer to Specifications. Mechanical Specifications
^ Measure wear of reverse baulk ring.
a. Place reverse baulk ring on Tool and then place reverse synchronizer cone on reverse baulk ring.
^ Make sure projection of synchronizer cone is positioned over the recess on Tool.
b. While holding reverse synchronizer cone against reverse baulk ring as firmly as possible, measure dimension "A" with dial indicator.
Wear limit (Dimension "A"): Refer to Specifications. Mechanical Specifications
c. If dimension "A" is smaller than the wear limit, replace baulk ring.
Bearing
^ Make sure bearings roll freely and are free from noise, cracks, pitting and wear.
ASSEMBLY
1. Place inserts in three grooves on coupling sleeve (3rd & 4th synchronizer).
2. Install 3rd input gear and 3rd baulk ring.
3. Press on 3rd & 4th synchronizer hub.
^ Pay attention to its direction.
4. Select proper snap ring of 3rd & 4th synchronizer hub to minimize clearance of groove, and then install it.
Allowable clearance of groove: 0-0.1 mm (0-0.004 inch)
Snap ring of 3rd & 4th synchronizer hub: Refer to Specifications. Mechanical Specifications
5. Install 4th input gear.
6. Select proper thrust washers to minimize clearance of groove. Then install them and thrust washer ring.
Allowable clearance of groove: 0-0.06 mm (0-0.0024 inch)
Input shaft thrust washer: Refer to Application and ID. Application and ID
7. Install 5th & reverse synchronizer assembly.
a. Hook insert springs on reverse baulk ring.
b. Install insert springs with reverse baulk ring onto coupling sleeve.
^ Pay attention to position of insert springs.
c. Place 5th baulk ring on 5th input gear.
d. Install reverse synchronizer cone on reverse baulk ring.
e. Place reverse synchronizer assembly on 5th input gear.
^ Mesh recesses of 5th input gear with projections of reverse synchronizer cone.
^ Put insert spring mounts on reverse baulk ring upon those on 5th baulk ring.
f. Press on 5th & reverse synchronizer assembly with 5th input gear.
8. Install input shaft front and rear bearings with Tool.
9. Measure gear end play as the final check. Refer to "DISASSEMBLY"
MAINSHAFT AND GEARS
DISASSEMBLY
1. Before disassembly, check 1st and 2nd main gear end plays.
Gear end play: Refer to Specifications. Mechanical Specifications
^ If not within specification, disassemble and check contact surface of gear, shaft and hub. Then check clearance of snap ring groove. Refer to "ASSEMBLY".
2. Press out mainshaft rear bearing with Tool.
3. Remove thrust washer and snap ring.
4. Press out 5th main gear and 4th main gear with Tool.
5. Press out 3rd main gear and 2nd main gear with Tool.
6. Remove snap ring.
7. Remove 1st & 2nd synchronizer and 1st main gear.
8. Remove mainshaft front bearing with Tool.
INSPECTION
Gear and shaft
^ Check shaft for cracks, wear and bending.
^ Check gears for excessive wear, chips and cracks.
Synchronizer
^ Check spline portion of coupling sleeves, hubs and gears for wear and cracks.
^ Check baulk rings for cracks and deformation.
^ Check insert springs for deformation.
^ Measure clearance between baulk ring and gear (1st).
Clearance between baulk ring and gear: Refer to Specifications. Mechanical Specifications
^ Measure wear of 2nd baulk rings.
a. Place baulk rings in position on synchronizer cone.
b. While holding baulk ring against synchronizer cone as far as it will go, measure dimensions "A" and "B".
Standard and wear limit: Refer to Specifications. Mechanical Specifications
c. If dimension "A" or "B" is smaller than the wear limit, replace baulk ring.
Bearing
^ Make sure bearings roll freely and are free from noise, cracks, pitting and wear.
^ When replacing tapered roller bearing, replace outer and inner race as a set.
ASSEMBLY
1. Press on 1st main gear, 1st baulk ring and 1st & 2nd synchronizer hub.
^ Pay attention to direction of 1st & 2nd synchronizer hub.
2. Select proper snap ring of 1st & 2nd synchronizer hub to minimize clearance of groove and then install it.
Allowable clearance of groove: 0-0.1 mm (0-0.004 inch)
Snap ring of 1st & 2nd synchronizer hub: Refer to Application and ID. Application and ID
3. Install 2nd synchronizer cone, inner & outer baulk rings. Insert springs and 1st & 2nd coupling sleeve.
4. Install 2nd main gear.
^ Ensure four protrusions of 2nd synchronizer cone are set in 2nd main gear holes.
5. Use Tool to press on 3rd main gear.
6. Use Tool to press on 4th main gear.
7. Use Tool to press on 5th main gear.
8. Select proper snap ring of 5th main gear to minimize clearance of groove and then install it.
Allowable clearance of groove: 0-0.15 mm (0-0.0059 inch)
Snap ring of 5th main gear: Refer to Application and ID. Application and ID
9. Press on thrust washer and press on mainshaft rear bearing.
10. Press on mainshaft front bearing.
11. Measure gear end play as the final check. Refer to "DISASSEMBLY"
FINAL DRIVE
DISASSEMBLY
1. Remove final gear.
2. Remove speedometer drive gear by cutting it.
3. Press out differential side bearings with Tool.
^ Be careful not to mix up the right and left bearings.
4. Drive out retaining pin and draw out pinion mate shaft.
5. Remove pinion mate gears and side gears.
INSPECTION
Gear, washer, shaft and case
^ Check mating surfaces of differential case, side gears and pinion mate gears.
^ Check washers for wear.
Bearing
^ Make sure bearings roll freely and are free from noise, cracks, pitting and wear.
^ When replacing tapered roller bearing, replace outer and inner race as a set.
ASSEMBLY
1. Install side gear and thrust washers in differential case.
2. Install pinion mate gears and thrust washers in differential case while rotating them.
^ When inserting, be careful not to damage pinion mate thrust washers.
^ Apply gear oil to gears, shafts, synchronizers and bearings when assembling.
3. Measure clearance between side gear and differential case with washers following the procedure below:
a. Set Tool and dial indicator on side gear.
b. Move side gear up and down to measure dial indicator deflection. Always measure indicator deflection on both side gears.
Clearance between side gear and differential case with washers: 0.1-0.2 mm (0.004-0.008 inch)
c. If not within specification, adjust clearance by changing thickness of side gear thrust washers.
Side gear thrust washer: Refer to Application and ID. Application and ID
4. Install retaining pin.
^ Make sure that retaining pin is flush with case.
6. Install final gear.
^ Apply locking sealant to final gear fixing bolts before installing.
7. Install speedometer drive gear.
8. Press on differential side bearings.
SHIFT CONTROL COMPONENTS
INSPECTION
^ Check contact surface and sliding surface for wear, scratches, projections and other damage.
CASE COMPONENTS
REMOVAL and INSTALLATION
Input shaft oil seal
^ Apply multi-purpose grease to seal lip of oil seal before installing.
Mainshaft Front Bearing Outer Race
^ Pull out oil channel (mainshaft) to remove front bearing outer race.
Mainshaft rear bearing outer race
Refer to Application and ID. Application and ID
Differential side bearing outer race
Refer to Application and ID. Application and ID
Input Shaft End Play and Differential Side Bearing Preload
If any of the following parts are replaced, adjust input shaft end play.
^ Input shaft
^ Input shaft bearing
^ Clutch housing
^ Transmission case
If any of the following parts are replaced, adjust differential side bearing preload.
^ Differential case
^ Differential side bearing
^ Clutch housing
^ Transmission case