Part 3

Transmission Disassemble

111. If clearance is out of specification, replace the 3rd gear, needle roller bearing, or input shaft.




112. Using V-blocks and a dial indicator, inspect the shaft for runout.

Maximum runout - 0.03 mm (0.0012 in)
If the runout exceeds the maximum, replace the input shaft.




113. Using a cylinder gage, measure the inside diameter of the 4th gear.

* Standard inside diameter - 42.009-42.025 mm (1.6539-1.6545 in)
* Maximum inside diameter - 42.025 mm (1.6545 in)

114. If the inside diameter exceeds the maximum, replace the 4th gear.
115. Using a cylinder gage, measure the inside diameter of the 3rd gear.

* Standard inside diameter - 43.009-43.025 mm (1.6933-1.6939 in)
* Maximum inside diameter - 43.025 mm (1.6939 in)

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




117. Coat the 4th gear cone with gear oil. Turn the No. 4 synchronizer ring in one direction while pushing it against the 4th gear cone. Check that the ring locks. If the No. 4 synchronizer ring does not lock, replace the ring or the 4th gear.




118. Using a feeler gage, measure the clearance between the No. 4 synchronizer ring back and 4th gear spline end.

Standard clearance - 0.7-1.45 mm (0.0276-0.0570 in)




119. Coat the 3rd gear cone with gear oil. Turn the synchronizer outer ring in one direction while pushing it against the 3rd gear cone. Check that the ring locks.
If the synchronizer outer ring does not lock, replace the ring or the 3rd gear.




120. Using a feeler gage, measure the clearance between the No. 3 synchronizer ring back and 3rd gear spline end.

Standard clearance - 0.65-1.75 mm (0.0276-0.0689 in)
If the clearance is out of specification, replace the No. 3 synchronizer ring.




121. Inspect the sliding condition between the No. 2 transmission hub sleeve and No. 2 transmission clutch hub.
122. Inspect the tip of the spline gear on the No. 2 transmission hub sleeve for wear. If any defects are found, replace the transmission hub sleeve or the transmission clutch hub.




123. Using a press (1), remove the output shaft rear bearing (inner race) and 4th driven gear.




124. Remove the output gear spacer from the output shaft.




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




126. Remove the No. 2 synchronizer ring set from the No. 1 transmission clutch hub.




127. Remove the 2nd gear needle roller bearing from the output shaft.




128. Remove the 2nd gear bearing spacer from the output shaft.




129. Remove the 2nd gear bushing from the output shaft.




130. Using a magnetic pick-up tool, remove the 2nd gear bushing ball (1) from the output shaft.




131. Using a press (1), remove the No. 1 transmission clutch hub and 1st gear from the output shaft.




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




133. Remove the 1st gear needle roller bearing from the output shaft.




134. Using a press (1), remove the output shaft front bearing (inner race) from the output shaft.




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




136. Using a feeler gage, measure the 1st gear thrust clearance.

Standard clearance - 0.25-0.40 mm (0.0098-0.0157 in)
If the clearance is out of specification, replace the 1st gear, or No. 1 transmission clutch hub.




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

Standard clearance - 0.10-0.35 mm (0.0039-0.0138 in)




138. Using V-blocks and a dial indicator, inspect the shaft for runout.

Maximum runout - 0.03 mm (0.0012 in)
If runout exceeds the maximum, replace the input shaft.




139. Using a cylinder gage, measure the inside diameter of the 2nd gear.

* Standard inside diameter - 50.009-50.025 mm (1.9689-1.9695 in)
* Maximum inside diameter - 50.025 mm (1.9695 in)

140. If the inside diameter exceeds the maximum, replace the 2nd gear.
141. Using a cylinder gage, measure the inside diameter of the 1st gear.

* Standard inside diameter - 51.009-51.025 mm (2.0082-2.0089 in)
* Maximum inside diameter - 51.025 mm (2.0089 in)

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




143. Coat the 2nd gear cone with gear oil.
144. Check for wear and damage.
145. Turn the synchronizer ring set in one direction while pushing it against the 2nd gear cone.
146. Check that the ring locks.
If the synchronizer ring set does not lock, replace the synchronizer ring set.




147. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end.

Standard clearance - 0.70-1.45 mm (0.0276-0.0571 in)
If the clearance is less than the minimum, replace the synchronizer ring set.
148. Coat the 1st gear cone with gear oil.




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




152. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end.

Standard clearance - 0.70-1.45 mm (0.0276-0.0571 in)
If the clearance is less than the minimum, replace the synchronizer ring set.




153. Using vernier calipers, measure the width of the reverse gear groove and thickness of the claw part on the No. 1 gear shift fork, and calculate the clearance.

Standard clearance - 0.15-0.35 mm (0.0059-0.0138 in) (A-B)
If the clearance is out of specification, replace the reverse gear and No. 1 gear shift fork with new ones.




154. Check the sliding condition between the No. 1 transmission clutch hub and the reverse gear.
155. Check the tip of the spline gear on the sleeve of the reverse gear for wear.
If any defects are found, replace the transmission hub sleeve or the transmission clutch hub.




156. Remove the speedometer drive gear from the front differential case assembly.




157. Put matchmarks (1) on the front differential ring gear and the front differential case.




158. Remove the bolts (1-16).
159. Using a plastic hammer, remove the front differential case.




160. Using a suitable tool (1), unstake the staked part of the front differential case.




161. Using a pin punch and a hammer, remove the front differential pinion shaft straight pin from the front differential case.




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




163. Remove the front differential pinions, front differential pinion thrust washers, front differential side gears, and front differential side gear thrust washers from the front differential case.
Remove the pinion thrust washers and side gear thrust washers while turning the front differential pinion.




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

Standard backlash - 0.05-0.20 mm (0.002-0.0079 in)
If the backlash is out of specification, install proper side gear thrust washers.




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

Minimum thickness - 0.09 mm (0.035 in)
If the thickness is less than the minimum, replace the front differential pinion thrust washer.




166. Using a micrometer, measure the outside diameter of the No. 1 front differential pinion shaft.

Minimum diameter - 17.975 mm (0.7076 in)
If the outer diameter is less than the minimum, replace the No. 1 front differential pinion shaft.