Part 3

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 gage, 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 gage, 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 gage, 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 gage, 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 gage, 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.