Part 1
ILLUSTRATED INDEXPart 1 Of 2:
Part 2 Of 2:
Refer to the drawing for transmission disassembly/reassembly.
Clean all the parts thoroughly in solvent and dry with compressed air.
OIL: Lubricate all the parts with oil before reassembly.
NOTE:
- This transmission uses no gaskets between the major housings; use liquid gasket (P/N 08718-0001 or 08718-0003)
- Always clean the magnet (66) whenever the transmission housing is disassembled.
- Inspect all the bearings for wear and operation.
TRANSMISSION HOUSING REMOVAL
NOTE: Place the clutch housing on two pieces of wood thick enough to keep the mainshaft from hitting the workbench.
1. Remove the back-up light switch.
2. Remove transmission hanger.
3. Remove the setting screws, washers, springs, and steel balls.
4. Loosen the transmission housing attaching bolts in a crisscross pattern in several steps, then remove them.
5. Remove the 32 mm sealing bolt.
6. Expand the snap ring on the countershaft ball bearing, and remove it from the groove using a pair of snap ring pliers.
7. Separate the transmission housing from the clutch housing, and wipe it clean of the sealant.
8. Remove the thrust shim, oil guide plate, and oil gutter plate from the transmission housing.
REVERSE SHIFT HOLDER CLEARANCE INSPECTION
1. Measure the clearance between the reverse shift fork and 5th/reverse shift piece pin.
2. If the clearances are more than the service limit, measure the widths of the groove in the reverse shift fork.
- If the widths of the grooves are not within the standard, replace the reverse shift holder with a new one.
- If the width of the grooves are within the standard, replace the 5th/reverse shift piece with a new one.
3. Measure the clearance between the reverse idler gear and the reverse shift fork.
4. If the clearances is more than the service limit, measure the width of the reverse shift fork.
- If the width is not within the standard, replace the reverse shift holder with a new one.
- If the width is within the standard, replace the reverse idler gear with a new one.
REVERSE IDLER GEAR REMOVAL
1. Remove the reverse shift holder.
2. Remove the reverse idler gear shaft and reverse idler gear.
MAINSHAFT, COUNTERSHAFT, SHIFT FORK DISASSEMBLY
1. Remove the interlock guide bolt from under the clutch housing.
2. Remove the shift arm B attaching bolt.
3. Remove the mainshaft and countershaft assemblies with the shift fork from the clutch housing.
NOTE: Before removing the mainshaft and countershaft assemblies, tape the mainshaft splines to protect the seal.
MAINSHAFT ASSEMBLY
Note the following during reassembly:
- The 3rd/4th and 5th synchro hubs are installed with a press.
- Install the angular ball bearing with the thin-edge outer race facing the 5th synchro hub.
- Install the ball bearing with the ball cage facing up.
OIL: Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to all contact surfaces the 3rd/4th and 5th synchro hubs.
Clearance Inspection
NOTE: If replacement is required, always replace the synchro sleeve and hub as a set.
1. Measure the clearance between 2nd and 3rd gears.
2. If the clearance is more than the service limit, measure the thickness of 3rd gear.
- If the thickness of 3rd gear is less than the service limit, replace 3rd gear with a new one.
- If the thickness of 3rd gear is within the service limit, replace the 3rd/4th synchro hub with a new one.
3. Measure the clearance between 4th gear and the spacer collar.
4. If the clearance is more than the service limit, measure distance (A) on the spacer collar.
5. If distance (A) is less than the service limit, replace the spacer collar with a new one. If distance (A) is within the service limit, measure the thickness of 4th gear.
- If the thickness of 4th gear is less than the service limit, replace 4th gear with a new one.
- If the thickness of 4th gear is within the service limit, replace the 3rd/4th synchro hub with a new one.
6. Measure the clearance between the spacer collar and 5th gear.
7. If the clearance is more than the service limit, measure distance (B) on the spacer collar.
8. If distance (B) is less than the service limit, replace the spacer collar with a new one. If distance (B) is within the service limit, measure thickness of 5th gear.
- If the thickness of 5th gear is less than the service limit, replace 5th gear with a new one.
- If the thickness of 5th gear is within the service limit, replace the 5th synchro hub with a new one.
Disassembly
1. Remove the ball bearing using a bearing puller as shown.
CAUTION: Remove the synchro hubs using a press and steel blocks as shown. Use of a jaw-type puller can cause damage to the gear teeth.
2. Support 4th gear on steel blocks, and press the mainshaft out of the 5th synchro hub as shown.
3. Support the 3rd gear on steel blocks, and press the mainshaft out of the 3rd/4th synchro hub as shown.
Inspection
1. Inspect the gear surface and bearing surface for wear and damage, then measure the mainshaft at points A, B, C, and D.
If any part of the mainshaft is less than the service limit, replace it with a new one.
2. Inspect for runout.
Standard: 0.02 mm (0.001 inch) maximum
Service Limit: 0.05 mm (0.002 inch)
NOTE: Support the mainshaft at both ends as shown.
If the runout is more than the service limit, replace the mainshaft with a new one.
Reassembly
CAUTION: When installing the 3rd/4th and 5th synchro hubs, support the shaft on steel blocks, and install the synchro hubs using a press.
NOTE: Refer reassembly sequence.
1. Support 2nd gear on steel blocks, then install the 3rd/4th synchro hub using the special tools and a press.
2. Install the 3rd/4th synchro sleeve by aligning the stops of the 3rd/4th synchro sleeve and hub.
NOTE: After installing, check the operation of the 3rd/4th synchro hub set.
3. Install the 5th synchro hub using the special tools and a press.
4. Install the ball bearing using the special tools and a press.
COUNTERSHAFT ASSEMBLY
NOTE: The 3rd, 4th, and 5th gears are installed with a press.
OIL: Prior to reassembling, clean all the parts in solvent, dry them and apply lubricant to all contact surfaces except the 3rd, 4th, and 5th gears.
Clearance Inspection
NOTE: If replacement is required, always replace the synchro sleeve and hub as a set.
1. Measure the clearance between the countershaft and 1st gear.
2. If the clearance is more than the service limit, measure the thickness of 1st gear.
- If the thickness of 1st gear is less than the service limit, replace 1st gear with a new one.
- If the thickness of 1st gear is within the service limit, replace the 1st/2nd synchro hub with a new one.
3. Measure the clearance between 2nd and 3rd gears.
4. If the clearance is more than the service limit, measure the thickness of the spacer collar.
5. If the thickness is less than the service limit, replace the spacer collar with a new one.
If the thickness is within the service limit, measure the thickness of 2nd gear.
- If the thickness of 2nd gear is less than the service limit, replace 2nd gear with a new one.
- If the thickness of 2nd gear is within the service limit, replace the 1st/2nd synchro hub with a new one.
Disassembly
CAUTION: Remove the gears using a press and steel blocks as shown. Use of a jaw-type puller can damage the gear teeth.
1. Securely clamp the countershaft assembly in a bench vise with wood blocks.
2. Raise the locknut tab from the groove of the countershaft, then remove the locknut and the spring washer.
3. Remove the bearings using a bearing puller as shown.
4. Support 4th gear on steel blocks, and press the countershaft out of 5th and 4th gears as shown.
5. Support 1st gear on steel blocks, and press the countershaft out of 3rd gear as shown.
Inspection
1. Inspect the gear surfaces and bearing surfaces for wear and damage, then measure the countershaft at points A, B, and C.
- If any part of the countershaft is less than the service limit, replace it with a new one.
2. Inspect for runout.
If the runout is more than the service limit, replace the countershaft with a new one.
Reassembly
CAUTION:
- Press the 3rd, 4th, and 5th gears on the countershaft without lubrication.
- When installing the 3rd, 4th, and 5th gears, support the shaft on steel blocks and install the gears using a press.
NOTE: Refer to reassembly sequence.
1. Install the needle bearing on the countershaft.
2. Assemble the parts as shown.
NOTE: Check that the fingers of the friction damper are securely set in the grooves of the 1st/2nd synchro hub.
3. Install the parts on the countershaft.
4. Support the countershaft on a steel block as shown and install 3rd gear using the special tools and a press.
5. Install 4th gear using the special tools and a press.
6. Install 5th gear using the special tools and a press.
7. Install the bearings in the direction shown using the special tools and a press.
CAUTION: Install the bearings with a maximum pressure of 7.8 kN (5,786 ft. lbs.).
8. Securely clamp the countershaft assembly in a bench vise with wood blocks.
9. Install the spring washer, tighten the locknut, then stake the locknut tab into groove.