Repair For Component Parts
Input Shaft and GearsDISASSEMBLY
1. Before disassembly, check 5th input gear end play.
Gear end play: 0.18 - 0.31 mm (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 mm (0.0394 - 0.0531 inch)
Wear limit 0.7 mm (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 mm (0 - 0.004 inch)
Snap ring of input shaft front bearing: Refer to Application and ID.
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 mm (0 - 0.004 inch)
Snap ring of 5th synchronizer: Refer to Application and ID.
Mainshaft and Gears
DISASSEMBLY
1. Before disassembly, measure gear end plays.
Gear end play:
1st main gear 0.18 - 0.31 mm (0.0071 - 0.0122 inch)
2nd, 3rd, 4th main gear 0.20 - 0.30 mm (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 mm (0.0394 - 0.0531 inch)
Wear limit 0.7 mm (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 mm (0 - 0.004 inch)
Mainshaft C-ring: Refer to Application and ID.
9. Install C-ring holder.
10. Press on mainshaft rear bearing.
11. Press on mainshaft front bearing.
12. Measure gear end play as the final check.
Final Drive
DISASSEMBLY
1. Remove final gear
2. Remove speedometer drive gear by cutting it.
3. Press out differential side bearings.
- 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 or wear.
- When replacing tapered roller bearing, replace outer and inner race as a set.
ASSEMBLY
1. Attach side gear thrust washers to side gears and install in differential case.
2. Install pinion mate washers and pinion mate gears.
3. Insert pinion mate shaft.
- When inserting, be careful not to damage pinion mate thrust washers.
4. 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) or less
c. If not within specification, adjust clearance by changing thickness of side gear thrust washers.
Side gear thrust washer: Refer to Application and ID.
5. 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 them.
7. Install speedometer drive gear and stopper.
8. Press on differential side bearings.
Shift Control Components
INSPECTION
- Check contact surface and sliding surface for wear, scratches, projections or other damage.
Case Components
Input shaft oil seal
1. Drive out input shaft oil seal.
2. Install input shaft oil seal.
- Apply multi-purpose grease to seal lip of oil seal before installing.
Input shaft rear bearing
1. Remove welch plug from transmission case.
2. Remove input shaft rear bearing by tapping it from welch plug hole.
3. Install welch plug.
- Apply recommended sealant to mating surface of transmission case.
4. Install input shaft rear bearing.
Mainshaft front bearing outer race and oil channel
1. Remove mainshaft front bearing outer race.
2. Remove oil channel.
3. Install oil channel.
- Ensure that the oil groove faces the oil pocket.
4. Install mainshaft front bearing outer race.