Part 3

Transmission Assemble

104. If the clearance exceeds the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft.





Note: Use a shop rag or piece of cloth to keep the snap ring from flying off.

105. Using 2 screwdrivers and a hammer, remove the input shaft rear bearing shaft snap ring from the input shaft.





Note: Support the input shaft assembly by hand to prevent it from dropping off.

106. Using a press (1), remove the input shaft rear radial ball bearing and 4th gear from the input shaft.




107. Remove the 4th gear needle roller bearing and 4th gear bearing spacer from the input shaft.




108. Remove the 4th gear synchronizer ring from the No. 2 transmission clutch hub.





Note: Use a shop rag or piece of cloth to keep the snap ring from flying off.

109. Using 2 screwdrivers and a hammer, remove the No. 2 clutch hub setting shaft snap ring from the input shaft.





Note: Support the input shaft assembly by hand to prevent it from dropping off.

110. Using a press (1), remove the No. 2 transmission clutch hub and 3rd gear from the input shaft.




111. Remove the 3rd gear synchronizer ring from the 3rd gear.




112. Remove the 3rd gear needle roller bearing from the input shaft.





Note: Use a shop rag or piece of cloth to keep the shifting keys and shifting key springs from flying off.

113. Remove the No. 2 transmission hub sleeve, shifting keys, and shifting key springs from the No. 2 transmission clutch hub.




114. Using a dial indicator, check the input shaft runout.

Maximum runout - 0.015 mm (0.0005 in)

115. If the runout exceeds the maximum, replace the input shaft.




116. Using a micrometer, measure the outer diameter of the input shaft journal surface at the locations indicated.

* Part 1 - 24.885-24.900 mm (0.9797-0.9803 in)
* Part 2 - 28.991-29.006 mm (1.1414-1.1420 in)
* Part 3 - 30.985-31.000 mm (1.2198-1.2204 in)
* Part 4 - 24.985-25.000 mm (0.9836-0.9842 in)

* Part 1 - 24.885 mm (0.9797 in)
* Part 2 - 28.991 mm (1.1414 in)
* Part 3 - 30.985 mm (1.2198 in)
* Part 4 - 24.985 mm (0.9836 in)

117. If any of the outer diameters are less than the minimum, replace the input shaft.




118. Using a cylinder gauge, measure the inside diameter of the 4th gear.

* Standard Inside Diameter - 34.015-34.031 mm (1.3391-1.3398 in)
* Maximum Inside Diameter - 34.031 mm (1.3398 in)

119. If the inside diameter exceeds the maximum, replace the 4th gear.




120. Using a cylinder gauge, measure the inside diameter of the 3rd gear.

* Standard Inside Diameter - 36.015-36.031 mm (1.4179-1.4185 in)
* Maximum Inside Diameter - 36.031 mm (1.4185 in)

121. If the inside diameter exceeds the maximum, replace the 3rd gear.




122. Inspect the 4th gear synchronizer ring, check for wear and damage.
123. Coat the 4th gear cone with gear oil.
124. Turn the synchronizer ring in one direction while pushing it against the 4th gear cone.
125. Check that the ring locks.
If the synchronizer ring does not lock, replace the synchronizer ring.




126. Using a feeler gauge, measure the clearance between the synchronizer ring and the gear spline end.

* Standard Clearance - 0.65-1.75 mm (0.0256-0.0689 in)
* Minimum Clearance - 0.65 mm (0.0256 in)

127. If the clearance is less than the minimum, replace the synchronizer ring.




128. Inspect the 3rd gear synchronizer ring. Check for wear and damage.
129. Coat the 3rd gear cone with gear oil.
130. Turn the synchronizer ring in one direction while pushing it against the 3rd gear cone.
131. Check that the ring locks.
If the synchronizer ring does not lock, replace the synchronizer ring.




132. Using a feeler gauge, measure the clearance between the synchronizer ring and the gear spline end.

* Standard Clearance - 0.75-1.65 mm (0.0295-0.0649 in)
* Minimum Clearance - 0.75 mm (0.0295 in)

133. If the clearance is less than the minimum, replace the synchronizer ring.




134. Using a feeler gauge, measure the 1st gear thrust clearance.

* Standard Clearance - 0.10-0.40 mm (0.0039-0.0157 in)
* Minimum Clearance - 0.40 mm (0.0157 in)

135. If the clearance exceeds the maximum, replace the 1st gear thrust washer, 1st gear or No. 1 transmission clutch hub.




136. Using a dial indicator, measure the 2nd gear thrust clearance.

* Standard Clearance - 0.10-0.55 mm (0.0039-0.0217 in)
* Minimum Clearance - 0.55 mm (0.0217 in)

137. If the clearance exceeds the maximum, replace the No. 1 transmission clutch hub, 2nd gear or 3rd driven gear.




138. Using a dial indicator, measure the 1st gear radial clearance.

* Standard Clearance, NSK made bearing - 0.015-0.056 mm (0.0005-0.0022 in)
* Standard Clearance, KOYO made bearing - 0.015-0.058 mm (0.0005-0.0022 in)
* Maximum Clearance, NSK made bearing - 0.056 mm (0.0022 in)
* Maximum Clearance, KOYO made bearing - 0.058 mm (0.0022 in)

139. If the clearance exceeds the maximum, replace the 1st gear, 1st gear needle roller bearing or input shaft.




140. Using a dial indicator, measure the 2nd gear radial clearance.

* Standard Clearance, NSK made bearing - 0.015-0.056 mm (0.0005-0.0022 in)
* Standard Clearance, KOYO made bearing - 0.015-0.058 mm (0.0005-0.0022 in)
* Maximum Clearance, NSK made bearing - 0.056 mm (0.0022 in)
* Maximum Clearance, KOYO made bearing - 0.058 mm (0.0022 in)

141. If the clearance exceeds the maximum, replace the 2nd gear, 2nd gear needle roller bearing or input shaft.




142. Using a press (1), remove the output shaft rear bearing and 4th driven gear from the output shaft.




143. Remove the output gear spacer (1) from the output shaft.




144. Using a press (1), remove the 3rd driven gear with the 2nd gear from the output shaft.




145. Remove the 2nd gear needle roller bearing (1) and 2nd gear bearing spacer from the output shaft.




146. Remove the No. 2 synchronizer ring set from the output shaft.





Note: Use a shop rag or piece of cloth to keep the shaft snap ring from flying off.

147. Using 2 screwdrivers and a hammer, remove the No. 1 clutch hub shaft snap ring from the output shaft.





Note: Support the input shaft by hand to prevent it from dropping off.

148. Using a press, remove the No. 1 clutch hub assembly and 1st gear from the output shaft.




149. Remove the No. 1 synchronizer ring set from the 1st gear.




150. Remove the 1st gear needle roller bearing (1) from the output shaft.




151. Remove the 1st gear thrust washer (1) from the output shaft.




152. Remove the 1st gear thrust washer pin or ball (1) from the output shaft.





Note: Use a shop rag or piece of cloth to keep the shifting keys and shifting key springs from flying off.

153. Remove the reverse gear, synchromesh shifting keys, and synchromesh shifting key springs from the No. 1 transmission clutch hub.




154. Using a dial indicator and V-blocks, check the output shaft runout.

Maximum Runout - 0.015 mm (0.0005 in)
If the runout exceeds the maximum, replace the output shaft.




155. Using a micrometer, measure the outer diameter of the output shaft journal surface at the locations indicated.

* Standard Outer Diameter, Part 1 - 31.985-32.000 mm (1.2592-1.2598 in)
* Standard Outer Diameter, Part 2 - 37.985-38.000 mm (1.4955-1.4961 in)
* Standard Outer Diameter, Part 3 - 32.985-33.000 mm (1.2986-1.2992 in)

156. If any of the outer diameters are less than the minimum, replace the output shaft.




157. Using a cylinder gauge, measure the inside diameter of the 2nd gear.

* Standard Inside Diameter - 38.015-38.031 mm (1.4967-1.4972 in)
* Maximum Inside Diameter - 38.031 mm (1.4972 in)

158. If the inside diameter exceeds the maximum, replace the 1st gear.
159. Using a cylinder gauge, measure the inside diameter of the 1st gear.

* Standard Inside Diameter - 44.015-44.031 mm (1.7328-1.7335 in)
* Maximum Inside Diameter - 44.031 mm (1.7335 in)

160. If the inside diameter exceeds the maximum, replace the 1st gear.




161. Using a micrometer, measure the 1st gear thrust washer.

* Standard Thickness - 5.975-6.025 mm (0.2352-0.2372 in)
* Minimum Thickness - 5.975 mm (0.2352 in)

162. If the thickness is less than the minimum, replace the 1st gear thrust washer.




163. Coat the 2nd gear cone and No. 2 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.
164. Install the inner ring onto the 2nd gear.




165. Install the middle ring onto the 2nd gear.




166. Install the outer ring onto the 2nd gear.




167. Check for wear and damage.
168. Turn the synchronizer ring set in one direction while pushing it against the 2nd gear cone.
169. Check that the ring set locks.
If the synchronizer ring set does not lock, replace the synchronizer ring set.




170. Using a feeler gauge, measure the clearance between the synchronizer ring and the gear spline end.

* Standard Clearance - 0.60-1.40 mm (0.0236-0.0551 in)
* Minimum Clearance - 0.60 mm (0.0236 in)

171. If the clearance is less than the minimum, replace the synchronizer ring set.




172. Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.
173. Install the inner ring onto the 1st gear.




174. Install the middle ring onto the 1st gear.




175. Install the outer ring onto the 1st gear.




176. Check for wear and damage.
177. Turn the synchronizer ring set in one direction while pushing it against the 1st gear cone.
178. Check that the ring set locks.
If the synchronizer ring set does not lock, replace the synchronizer ring set.




179. Using a feeler gauge, measure the clearance between the synchronizer ring and the gear spline end.

* Standard Clearance - 0.60-1.40 mm (0.0236-0.0551 in)
* Minimum Clearance - 0.60 mm (0.0236 in)

180. If the clearance is less than the minimum, replace the synchronizer ring set.




181. Remove the speedometer drive gear from the front differential case.




182. Place matchmarks (1) on the front differential ring gear and the front differential case.




183. Remove the bolts (1-6).
184. Using a plastic hammer, remove the front differential ring gear from the front differential case.




185. Fix the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.

Standard Backlash - 0.05 to 0.20 mm (0.0020 to 0.0079 in)

186. If the backlash is out of the specification, replace the side gear thrust washers.




187. Using a chisel and a hammer, loosen the staked part of the front differential case.




188. Using a pin punch (3 mm) and a hammer, remove the front differential pinion shaft straight pin from the front differential case.




189. Remove the front No. 1 differential pinion shaft from the front differential case.





Note: While rotating the front differential pinion, remove the pinions and side gears.

190. Remove the front differential pinions, front differential pinion thrust washers, No. 1 front differential side gear thrust washers, and front differential side gears from the front differential case.




191. Using a micrometer, measure the thickness of the front differential pinion thrust washer.

Minimum Thickness - 0.94 mm (0.0370 in)

192. If the thickness is less than the minimum, replace the front differential pinion thrust washer.




193. Using a micrometer, measure the outer diameter of the front No. 1 differential pinion shaft.

Minimum Outer Diameter - 16.982 mm (0.6685 in)

194. If the outer diameter is less than the minimum, replace the front No. 1 differential pinion shaft.