5. Shafts and Clutches, Disassemble & Service

Mainshaft Disassembly, Inspection, and Reassembly





1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
2. Inspect the splines for excessive wear and damage.
3. Check shaft bearing surface for scoring and excessive wear.
4. Before installing the O-rings, wrap the shaft splices with tape to prevent O-ring damage.
5. Lubricate all parts with ATF during assembly.
6. Install the conical spring washer and 41 x 68 mm thrust washer in the direction shown.
7. Replace the locknut and conical spring washer with new ones when assembling the transmission.
8. Check the clearance of the 3rd gear.

Mainshaft 3rd Gear Clearance Inspection
1. Remove the mainshaft transmission housing bearing.





2. Assemble the 41 x 68 mm thrust washer (A), 3rd/4th clutch (B), 4th gear collar (C), and the transmission housing bearing (D) on the mainshaft (E). Do not install the O-rings during inspection.
3. Install the idler gear (F) on the mainshaft with a press, then install the conical spring washer (G) and locknut (H).
4. Tighten the locknut to 29 Nm (3.0 kgf-cm, 22 ft. lbs.).





5. Measure the clearance between the mainshaft flange (A) and 41 x 68 mm thrust washer (B) with a feeler gauge (C) in at least three places. Use the average as the actual clearance.
Standard: 0.03 - 0.31 mm (0.001 - 0.012 inch)





6. If the clearance is out of standard, remove the 41 x 68 mm thrust washer and measure its thickness.





7. Select and install a new thrust washer, then recheck.
8. After replacing the thrust washer, make sure the clearance is within standard.
9. Disassemble the shaft and gears.
10. Reinstall the bearing in the transmission housing.

Countershaft Disassembly, Inspection, and Reassembly

NOTE: Some reverse selector hubs are press-fitted to the countershaft; special tools are needed to remove them and to install them.





1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
2. Inspect the splines for excessive wear and damage.
3. Check shaft bearing surface for scoring and excessive wear.
4. Lubricate all parts with ATF during assembly.
5. Install the conical spring washer, reverse selector, 35 x 47 x 7.8 mm collar, 3rd gear, 1st gear, and 2nd gear in the direction shown.
6. Replace the locknut and conical spring washer with new ones when assembling the transmission. The countershaft locknut has left-hand threads.

Countershaft Reverse Selector Hub Removal





1. Remove the reverse selector hub (A) and the 4th gear (B) from the countershaft with a press. Place a shaft protector (C) between the countershaft and press to prevent damaging the countershaft.

NOTE: Some reverse selector hubs are not press fitted and can be removed without using a press.

2. Remove the needle bearing, set ring, 35 x 47 x 7.8 mm collar, 31 mm cotters, and 37 x 41 x 82.8 mm collar from the countershaft.
3. Remove 1st, 3rd ,and 2nd gears from the countershaft by hand.

Countershaft Reverse Selector Hub Installation

Special Tools Required
Driver 40 mm I.D.07746-0030100

1. Apply ATF to the parts.
2. Install 2nd, 1st, and 3rd gears on the countershaft by hand.
3. Install the 37 x 41 x 82.8 mm collar, 31 mm cotters, 35 x 47 x 7.8 mm collar, set ring needle bearing, and 4th gear on the countershaft.





4. Slide the reverse selector hub (A) over the countershaft (B), then press it in place with the special tool and a press.

NOTE: Some reverse selector hubs are not press fitted and can be installed without using the special tool and a press.

Secondary Shaft Disassembly, Inspection, and Reassembly





1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.
2. Inspect the splines for excessive wear and damage.
3. Check the shaft bearing surfaces for scoring and excessive wear.
4. Before installing the O-rings, wrap the shaft splines with tape to prevent O-ring damage.
5. Lubricate all parts with ATF during assembly.
6. Install the conical spring washer and idler gear in the direction shown.
7. Replace the locknut and conical spring washer with new ones when assembling the transmission. The secondary shaft locknut has left-hand threads.
8. Check the clearance of 2nd and 1st gears.

Secondary Shaft Ball Bearing, Idler Gear Removal and Installation

Special Tools Required
Attachment, 42 mm I.D. 07QAD-P0A0100

Removal





Place a shaft protector (A) on the secondary shaft (B), place the puller (C) on the idler gear (D), then remove the idler gear and ball bearing (E).

Installation





Install the idler gear (A) on the secondary shaft (B), and install the ball bearing (C) on the shaft with the special tool and a press.

Secondary Shaft 2nd Gear Clearance Inspection





1. Install the thrust needle bearing (A), needle bearing (B), 2nd gear (C), thrust needle bearing (D), 37 x 58 mm thrust washer (E), and 2nd clutch (F) on the secondary shaft (G), then secure them with the snap ring (H).





2. Measure the clearance between the snap ring (A) and the 2nd clutch guide (B) with a feeler gauge (C), in at least three places. Use the average as the actual clearance.
Standard: 0.04 - 0.12 mm (0.002 - 0.005 inch)
3. If the clearance is out of standard, remove the 37 x 58 mm thrust washer and measure its thickness.





4. Select and install a new thrust washer, then recheck.
5. After replacing the thrust washer, make sure the clearance is within standard.
6. Disassemble the shaft and gears.

Secondary Shaft 1st Gear Clearance Inspection

Special Tools Required
Attachment, 42 mm I.D. 07QAD-POA0100





1. Install the thrust needle bearing (A), needle bearing (B), 1st gear (C), thrust needle bearing (D), 40 x 51.5 mm thrust washer (E), 1st clutch (F), and 27 x 45 x 44 mm collar (G) on the secondary shaft (H).





2. Install the idler gear (I), then install the ball bearing (J) on the idler gear with the special tool and a press.
3. Install the conical spring washer (K) and locknut (L), then tighten the locknut to 29 Nm (3.0 kgf-cm, 22 ft. lbs.).





4. Turn the secondary shaft assembly upside down, and set the dial indicator (A) on the 1st gear (B).





5. Hold the secondary shaft, and measure the 1st gear axial clearance in at least three places while moving the 1st gear (A). Use the average as the actual clearance.
Standard: 0.04 - 0.12 mm (0.002 - 0.005 inch)
6. If the clearance is out of standard, remove the 40 x 51.5 mm thrust washer and measure its thickness.





7. Select and install a new thrust washer, then recheck.
THRUST WASHER, 40 x 51.5 mm
8. After replacing the thrust washer, make sure the clearance is within standard.
9. Disassemble the shaft and gears.

Idler Gear Shaft Removal and Installation





1. Remove the snap ring (A), cotter retainer (B), and cotters (C). Do not distort the snap ring.
2. Remove the idler gear shaft/idler gear assembly (D) from the transmission housing.
3. Check the snap rings and cotter retainer for wear and damage. Replace them if they are worn, distorted, or damaged.
4. Install the idler gear and shaft in the reverse order of removal.

Idler Gear/Idler Gear Shaft Replacement

Special Tools Required
^ Driver 07749-0010000
^ Attachment, 32 x 35 mm 07746-0010100





1. Remove the snap ring from the idler gear/idler shaft assembly.





2. Remove the idler gear shaft (A) from the idler gear (B) with the special tools and a press.





3. Replace the idler gear or idler gear shaft, and attach the idler gear shaft to the idler gear.





4. Install the idler gear shaft (A) in the idler gear (B) with the special tools and a press.
5. Install the snap ring.

Clutch Disassembly

Special Tools Required
^ Clutch spring compressor attachment 07LAE-PX40100
^ Clutch spring compressor attachment 07HAE-PL50100
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A





1. Remove the snap ring with a screwdriver.





2. Remove the clutch end plate (A), clutch discs (5) (B), clutch waved-plates (5) (C), and waved spring (D) from the 1st clutch drum (E).





3. Remove the clutch end plate (A), clutch discs (5) (B), clutch waved-plates (3) (C), clutch flat-plates (2) (D), and waved spring (E) from the 2nd clutch drum (F).
4. Make reference marks on the clutch flat-plates (D).





5. Remove the clutch end plate (A), clutch discs (3) (B), clutch waved-plates (3) (C), and waved spring (D) from the 3rd clutch drum (E).





6. Remove the clutch end plate (A), clutch discs (3) (B), clutch waved-plates (3) (C), and waved spring (D) from the 4th clutch drum (E).





7. Install the special tools.





8. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 3rd and 4th clutches.





9. Set the special tool (A) on the spring retainer (B) of the 1st and 2nd clutches in such a way that the special tool works on the clutch return spring (C).





10. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.





11. Compress the return spring until the snap ring can be removed.





12. Remove the snap ring with snap ring pliers.
13. Remove the special tools.





14. Remove the snap ring (A), spring retainer (B), and return spring (C).





15. Wrap a shop rag around the clutch drum (A), and apply air pressure to the fluid passage to remove the piston (B). Place a finger tip on the other passage while applying air pressure.





16. Remove the piston, then remove the O-rings from the 3rd and 4th clutch pistons.





17. Remove the piston, then remove the O-ring from the 1st and 2nd clutch drum, and remove the O-ring from each clutch piston.

Clutch Inspection





1. Inspect the 3rd and 4th clutch pistons and clutch piston check valves.
2. If the clutch piston check valve is loose or damaged, replace the clutch piston.
3. Check the spring retainer for wear and damage.





4. Check the oil seal on the spring retainer of the 1st and 2nd clutches for wear, damage, and peeling.
5. If the oil seal is worn, damaged, or peeling, replace the spring retainer.
6. Inspect the clutch discs, clutch plates, and clutch end plate for wear, damage, and discoloration.
Standard Thickness
Clutch Discs: 1.94 mm (0.076 inch)
Clutch Plates:
1st clutch plates: 1.6 mm (0.063 inch)
2nd clutch plates: 2.0 mm (0.079 inch)
3rd and 4th clutch plates: 2.0 mm (0.079 inch)
7. If the clutch discs are worn or damaged, replace them as a set. If the clutch discs are replaced, inspect the clutch end-plate-to-top-disc clearance.
8. If any plate is worn, damaged, or discolored, replace the damaged plate with the new plate, and inspect the other waved-plates for a phase difference. If the clutch plate is replaced, inspect the clutch end-plate-to-top-disc clearance.
9. If the clutch end plate is worn, damaged, or discolored, inspect the clutch end-plate-to-top-disc clearance, then replace the clutch end plate.

Clutch Waved-plate Phase Difference Inspection





1. Place the clutch waved-plate (A) on a surface plate, and set a dial indicator (B) on the waved-plate.
2. Find the bottom (D) of a phase difference of the waved-plate, zero the dial indicator and make a reference mark on the bottom of the waved-plate.
3. Rotate the 1st and 2nd clutch waved-plate about 60 degrees by holding it by its circumference, and rotate the 3rd and 4th clutch waved-plate about 72 degrees or 54 degrees apart from the bottom. The dial indicator should be at a top (E) of a phase difference. Do not rotate the waved-plate by holding its surface, always rotate it holding its circumference.
4. Read the dial indicator. The dial indicator reads the phase difference (C) of the waved-plate between bottom and top.
Standard: 0.07 - 0.20 mm (0.003 - 0.008 inch)
Minimum: 0.05 mm (0.002 inch)
5. Rotate the 1st and 2nd clutch waved-plate about 60 degrees from the top position, and rotate the 3rd and 4th clutch waved-plate 54 degrees or 72 degrees apart from the top. The dial indicator should be at the bottom of a phase difference (F and H). Zero the dial indicator.
6. Measure the phase difference at the other two tops (G and 1) of the waved-plate by following steps 3 thru 5.
7. If the two values of the three measurements are within the standard, the waved-plate is OK. If the two values of the three measurements are out of the standard, replace the waved-plate.

Clutch Clearance Inspection

Special Tools Required
Clutch compressor attachment 07ZAE-PRP0100

1. Inspect the clutch piston, discs, plates, and end plate for wear and damage and inspect clutch waved-plate phase difference, if necessary.





2. Install the clutch piston in the clutch drum. Do not install the O-rings during inspection.





3. Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (5) (C) and discs (5) (D), then install the clutch end-plate (E) with the flat side toward the disc.





4. Install the waved spring (A) in the 2nd clutch drum (B). Install the clutch flat-plate (C), clutch disc (D), and clutch flat-plate (E). Starting with the clutch disc, alternately install the clutch discs (4) (F) and clutch waved-plates (3) (G), then install the clutch end plate (H) with the flat side toward the disc.





5. Install the waved spring (A) in the 3rd clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (3) (C) and discs (3) (D), then install the clutch end plate (E) with the flat side toward the disc.





6. Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (3) (C) and discs (3) (D), then install the clutch end plate (E) with the flat side toward the disc.





7. Install the snap ring with a screwdriver.





8. Set a dial indicator (A) on the clutch end plate (B).
9. Zero the dial indicator with the clutch end plate lifted up to the snap ring (C).





10. Release the clutch end plate to lower the clutch end plate, then put the special tool on the end plate (A).
11. Press the special tool down with 150 - 160 N (15 - 16 kgf, 33 - 35 lbs.) using a force gauge, and read the dial indicator (B). The dial indicator reads the clearance (C) between the clutch end plate and top disc (D). Take measurements in at least three places, and use the average as the actual clearance.
Clutch End Plate-to-Top Disc Clearance
Service Limit:
1st Clutch: 1.28 - 1.48 mm (0.050 - 0.058 inch)
2nd Clutch: 0.85 - 1.05 mm (0.033 - 0.041 inch)
3rd Clutch: 0.73 - 0.93 mm (0.029 - 0.037 inch)
4th Clutch: 0.73 - 0.93 mm (0.029 - 0.037 inch)





12. If the clearance is out of the service limit, select a new clutch end plate from the following table.





1st CLUTCH END PLATES





2nd CLUTCH END PLATES





3rd and 4th CLUTCH END PLATES

13. Install the new clutch end plate, then recheck the clearance.

NOTE: If the thickest clutch end plate is installed, but the clearance is still over the service limit, replace the clutch discs and plates.

Clutch Reassembly

Special Tools Required
^ Clutch spring compressor attachment 07LAE-PX40100
^ Clutch spring compressor attachment 07HAE-PL50100
^ Clutch spring compressor bolt assembly 07GAE-PG40200 or 07GAE-PG4020A

1. Soak the clutch discs thoroughly in ATF for a minimum of 30 minutes.





2. Install the new O-rings (A) on the 3rd and 4th clutch pistons (B).





3. Install the new O-ring (A) in the 1st and 2nd clutch pistons (B), and install the new O-ring (C) on the clutch drums (D).





4. Install the clutch piston (A) in the clutch drum (B). Apply pressure and rotate it to ensure proper seating. Lubricate the piston O-ring with ATF before installing. Do not pinch the O-ring by installing the piston with too much force.





5. Install the return spring (A) and spring retainer (B), and position the snap ring (C) on the retainer.





6. Install the special tools.





7. Be sure the special tool (A) is adjusted to have full contact with the spring retainer (B) on the 3rd and 4th clutches.





8. Set the special tool (A) on the spring retainer (B) of the 1st and 2nd clutches in such a way that the special tool works on the clutch return spring (C).





9. If either end of the special tool is set over an area of the spring retainer which is unsupported by the return spring, the retainer may be damaged.





10. Compress the return spring.





11. Install the snap ring with snap ring pliers.
12. Remove the special tools.





13. Install the waved spring (A) in the 1st clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (5) (C) and discs (5) (D), then install the clutch end plate (E) with the flat side toward the disc.





14. Install the waved spring (A) in the 2nd clutch drum (B). Install the clutch flat-plate (C), clutch disc (D), and clutch flat-plate (E). Starting with the clutch disc, alternately install the clutch discs (4) (F) and clutch waved-plates (3) (G), then install the clutch end-plate (H) with the flat side toward the disc.





15. Install the waved spring (A) in the 3rd clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (3) (C) and discs (3) (D), then install the clutch end-plate (E) with the flat side toward the disc.





16. Install the waved spring (A) in the 4th clutch drum (B). Starting with the clutch waved-plate, alternately install the clutch plates (3) (C) and discs (3) (D), then install the clutch end-plate (E) with the flat side toward the disc.





17. Install the snap ring with a screwdriver.
18. Check that the clutch piston moves by applying air pressure into fluid passage.