Part 2
SHIFT FORK ASSEMBLY
OIL: Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact parts.
Clearance Inspection
NOTE: The synchro sleeve and the synchro hub should be replaced as a set.
1. Measure the clearance between each shift fork and its matching synchro sleeve.
2. If the clearance is more than the service limit, measure the thickness of the shift fork fingers.
- If the thickness of the shift fork fingers is not within the standard, replace the shift fork with a new one.
- If the thickness of the shift fork fingers is within the standard, replace the synchro sleeve with a new one.
3. Measure the clearance between the shift piece or shift fork and the shift arm B.
4. If the clearance is more than the service limit, measure the groove of the shift piece or shift fork.
- If the groove of the shift piece or shift fork is not within the standard, replace the shift piece or shift fork with a new one.
- If the groove of the shift piece or shift fork is within the standard, replace the shift arm B with a new one.
MBS SHIFT PIECE INSPECTION
1. Measure the width of the MBS shift piece.
If the width of the MBS shift piece is less than the service limit, replace the MBS shift piece.
SYNCHRO RING, GEAR INSPECTION
Inspection / Installation
1. Inspect gear teeth on all synchro hubs and synchro sleeves for rounded off corners, which indicate wear.
2. Install each synchro hub in its mating synchro sleeve, and check for freedom of movement.
NOTE: If replacement is required, always replace the synchro sleeve and synchro hub as a set.
3. When assembling the synchro sleeve and synchro hub, be sure to match the three sets of longer teeth (120 degrees apart) on the synchro sleeve with the three sets of deeper grooves in the synchro Hub.
CAUTION: Do not install the synchro sleeve with its longer teeth in the synchro hub slots because it will damage the spring ring.
SYNCHRO SLEEVE, SYNCHRO HUB INSPECTION / INSTALLATION
1. Inspect the synchro ring and gear.
2. Coat the cone surface of the gear with oil, and place the synchro ring on the matching gear. Rotate the synchro ring, making sure that it does not slip.
Measure the clearance between the synchro ring and gear all the way around.
NOTE: Hold the synchro ring against the gear evenly while measuring the clearance.
Synchro Ring-to-Gear Clearance:
Standard: 0.73 - 1.18 mm (0.029 - 0.046 inch)
Service Limit: 0.4 mm (0.02 inch)
If the clearance is less than the service limit, replace the synchro ring and synchro cone.
SHIFT ROD REMOVAL
NOTE: The steel balls are all of the same size (5/16 inch).
1. Remove the differential assembly.
2. Remove the 28 mm plug bolt and 1st/2nd select spring.
3. Remove the shift arm C attaching bolt.
4. Remove the shift arm shaft.
NOTE: Be careful not to lose the steel ball.
5. Remove the steel ball, spring, and collar.
6. Remove shift arms C and B, and the interlock, then remove the reverse select spring and retainer.
7. Remove the shift arm A attaching bolt, the set ball spring bolt, set spring, and steel ball.
8. Remove the shift rod, then remove the shift arm A.
9. Remove the reverse lock cam.
10. Remove the magnet.
DIFFERENTIAL
Backlash Inspection
1. Place differential assembly on V-blocks, and install both driveshafts.
2. Measure backlash of both pinion gears.
Standard (New): 0.05 - 0.15 mm (0.002 - 0.006 inch)
3. If the backlash is not within the standard, replace the differential carrier.
Bearing Replacement
NOTE: Check bearings for wear and rough rotation. If the bearings are OK, removal is not necessary.
1. Remove the ball bearings using a bearing puller as shown.
2. Install new ball bearings using the special tool as shown.
NOTE: Drive the bearings squarely until they bottom against the carrier.
Final Driven Gear Replacement
1. Remove the bolts in a crisscross pattern in several steps, then remove the final driven gear from the differential carrier.
NOTE: The final driven gear bolts have left-hand threads.
2. Install the final driven gear by tightening the bolts in a crisscross pattern in several steps.
Thrust Shim Adjustment
1. Install the differential assembly, making sure it bottoms in the clutch housing, using the special tool as shown.
2. Install the thrust shim.
NOTE: Install the same size thrust shim that was removed.
3. Install the transmission housing.
NOTE: Do not apply liquid gasket to the mating surface of the clutch housing.
4. Tighten the transmission housing attaching bolts.
8 x 1.25 mm
27 Nm (20 ft. lbs.)
5. Use the special tool to bottom the differential assembly in the clutch housing.
6. Measure clearance between thrust shim and bearing outer race in transmission housing.
7. If the clearance is more than the standard, select a new thrust shim from the table.
NOTE: If the clearance measured in step 6 is within the standard, go to step 10.
8. Remove the bolts and transmission housing.
9. Replace the thrust shim selected in step 7, then recheck the clearance.
10. Remove the bolts and transmission housing. Apply liquid gasket to the surface of the transmission housing and reassemble.
CLUTCH HOUSING BEARING REPLACEMENT
Mainshaft
1. Remove the ball bearing using the special tool as shown.
2. Remove the oil seal from the clutch housing.
3. Drive the new oil seal into the clutch housing using the special tools as shown.
4. Drive the ball bearing into the clutch housing using the special tools as shown.
Countershaft
1. Remove the needle bearing using the special tool as shown, then remove the oil guide plate.
2. Install the oil guide plate, then drive the needle bearing into the clutch housing using the special tools as shown.
MAINSHAFT THRUST SHIM ADJUSTMENT
1. Remove the thrust shim and oil guide plate from the transmission housing.
2. Install the 3rd/4th synchro hub, spacer collar, 5th synchro hub, ball bearing, and thrust washer on the mainshaft. Install the assembly in the transmission housing.
3. Measure the distance (B) between the end of the transmission housing and thrust washer.
NOTE:
- Use a straight edge and vernier caliper.
- Measure at three locations and average the readings.
4. Measure the distance (C) between the surfaces of the clutch housing and bearing inner race.
NOTE:
- Use a straight edge and depth gauge.
- Measure at three locations and average the readings.
5. Select the proper shim on the basis of the following calculations:
NOTE: Use only one thrust shim.
6. Install the oil guide plate and selected thrust shim in the transmission housing.
NOTE:
- Clean the thrust washer, spring washer and thrust shim thoroughly before installation.
- Install the thrust washer, spring washer and thrust shim properly.
7. Install the thrust washer and spring washer in the mainshaft.
8. Install the mainshaft in the clutch housing.
9. Place the transmission housing over the mainshaft and onto the clutch housing.
10. Tighten the clutch and transmission housings with several 8 mm bolts.
NOTE: It is not necessary to use sealing agent between the housings.
8 x 1.25 mm
27 Nm (20 ft. lbs.)
11. Tap the mainshaft with a plastic hammer.
12. Check the thrust clearance in the manner described.
CAUTION: Measurement should be made at room temperature.
a. Slide the mainshaft base and the collar over the mainshaft.
b. Attach the mainshaft holder to the mainshaft as follows:
NOTE:
- Back-out the mainshaft holder bolt and loosen the two hex bolts.
- Fit the holder over the mainshaft so its lip is toward the transmission.
- Align the mainshaft holder's lip around the groove at the inside of the mainshaft splines, then tighten the hex bolts.
c. Seat the mainshaft fully by tapping on the end with a plastic hammer.
d. Thread the mainshaft holder bolt in until it just contacts the wide surface of the mainshaft base.
e. Zero a dial gauge on the end of the mainshaft.
f. Turn the mainshaft holder bolt clockwise: stop turning when the dial gauge has reached its maximum movement. The reading on the dial gauge is the amount of mainshaft end play.
CAUTION: Turning the mainshaft holder bolt more than 60 degrees after the needle of the dial gauge stops moving may damage the transmission.
g. If the reading is within the standard, the clearance is correct.
If the reading is not within the standard, recheck the shim thickness.
Standard: 0.11 - 0.18 mm (0.004 - 0.007 inch)
TRANSMISSION REASSEMBLY
NOTE: The steel balls are all of the same size (5/16 inch).
1. Install the magnet and reverse lock cam.
2. Set shift arm A on the clutch housing, then install the shift rod.
3. Install the spring washer and shift arm A attaching bolt.
4. Install the steel ball, spring, and set ball spring bolt.
5. Install shift arm B in the interlock, then set it on the clutch housing.
6. Insert shift arm shaft in the clutch housing.
7. Install the collar, spring, and steel ball into the case. Compress the ball and insert the shift arm shaft.
8. Install shift arm C in shift arm A, then insert the shift arm shaft.
9. Install the reverse select retainer and reverse select spring onto shift arm shaft.
10. Install the differential assembly.
11. Position the 36 mm spring washer and washer onto the mainshaft bearing.
12. Install the mainshaft, countershaft, and shift fork assemblies.
NOTE: Align the finger of the interlock with the groove in the shift fork shaft.
13. Install the spring washer and shift arm B attaching bolt.
14. Install the 1st/2nd select spring, 28 mm plug bolt, and interlock guide bolt.
NOTE: Apply liquid gasket (P/N 08718-0001 or 08718-0003) to the threads of the 28 mm plug bolt and interlock guide bolt.
15. Install the reverse idler gear and reverse idler gear shaft.
16. Install the reverse shift holder.
17. Install the oil gutter plate.
18. Install the oil guide plate and thrust shim on the transmission housing.
19. Apply liquid gasket to the surface of the transmission housing mating with the clutch housing as shown.
NOTE:
- Use liquid gasket (P/N 08718-0001 or 08718-0003).
- Remove the dirty oil from the sealing surface.
- If 5 minutes have passed after applying liquid gasket, reapply it and assemble the housings.
- Allow it to cure at least 20 minutes after assembly before filling the transmission with oil.
20. Install the dowel pins and the transmission housing.
21. Lower the transmission housing with the snap ring pliers, and set the snap ring into the groove of the countershaft bearing.
NOTE: Check that the snap ring is securely seated in the groove of the countershaft bearing.
22. Install the 32 mm sealing bolt.
NOTE: Apply liquid gasket (P/N 08718-0001 or 08718-0003) to the threads.
23. Tighten the transmission housing attaching bolts in the numbered sequence in several steps shown.
24. Install the steel balls, springs, and set screws.
25. Install the back-up light switch and transmission hanger.