Counter Shaft and Gear

Disassembly





1. Using a press to remove 3rd counter gear, 3rd-4th synchronizer assembly, 4th counter gear, 4th needle bearing, 4th gear bushing, 4th counter gear thrust washer and counter rear bearing inner race.
2. Remove 3rd needle bearing.





3. Using a press to remove 3rd gear bushing.

CAUTION:
Never use oil hole of 3rd gear bushing when press out.

Assembly





1. Using the inserter [SST: ST30911000 ( - )] and a press to press fit 3rd gear bushing onto counter shaft.

2. Install 3rd-4th coupling sleeve and 3rd-4th shifting inserts into 3rd-4th synchronizer hub.

CAUTION:

^ Install 3rd-4th coupling sleeve with the thicker flange faced the front side.
^ Never reuse 3rd-4th coupling sleeve and 3rd-4th synchronizer hub.
^ Replace 3rd-4th coupling sleeve and 3rd-4th synchronizer hub as a set.

3. Install 3rd-4th spread springs in 3rd-4th shifting inserts.

CAUTION:

^ Never install 3rd-4th spread spring hook onto the same 3rd4th shifting insert.

^ Be careful with the shape of reverse shifting insert to avoid misassembly.





4. Apply recommended grease to 3rd needle bearing.
5. Apply gear oil to the hole spline press fitting side of 3rd-4th synchronizer hub.
6. Install 3rd needle bearing, 3rd counter gear, 3rd inner baulk ring, 3rd synchronizer cone and 3rd outer baulk ring on counter shaft and then using the inserter [SST: ST30911000 ( - )] and a press to press fit 3rd-4th synchronizer assembly.

CAUTION:
Replace 3rd inner baulk ring, 3rd synchronizer cone and 3rd outer baulk ring as a set.

NOTE:





4th baulk ring has three spaces that one gear tooth is missing but 3rd baulk ring doesn't.





7. Apply recommended grease to 4th needle bearing.
8. Install 4th outer baulk ring, 4th synchronizer cone, 4th inner baulk ring, 4th needle bearing and 4th counter gear onto counter shaft and then using the inserter [SST: KV40100630 (J-26092)] and a press to press fit 4th gear bushing and 4th counter gear thrust washer.

CAUTION:
Replace 4th outer baulk ring, 4th synchronizer cone and 4th inner baulk ring as a set.





9. Using the inserter [SST: ST30032000 (J-26010-01)] and a press to press fit counter rear bearing inner race onto counter shaft.

CAUTION:
Replace counter rear bearing inner race, counter rear bearing and counter rear bearing spacer as a set.

Inspection

COUNTER SHAFT AND GEAR





If the contact surface on each gear and counter shaft, etc. has damage, peeling, abrasion, dent, bent, or any other damage, replace the components.

SYNCHRONIZER

Synchronizer Hub and Coupling Sleeve





^ If the contact surface on coupling sleeve, synchronizer hub, and shifting insert has damage or abrasion, replace the components.
^ Coupling sleeve and synchronizer hub shall move smoothly.

Baulk Ring and Spread Spring





^ If the cam surface on baulk ring or contact surface on insert has damage or excessive wear, replace with a new one.
^ If spread spring is damaged, replace with a new one.

Baulk Ring Clearance for Double Cone Synchronizer (4th)





^ Check the clearance between outer baulk ring (1), synchronizer cone (2), and inner baulk ring (3) as follows.

CAUTION:
The clearances "A" and "B" are controlled with outer baulk ring, synchronizer cone, and inner baulk ring as a set. Replace them as a set if the clearances are outside the limit value.





1. Measure the clearance "A" at 2 points or more diagonally opposite using a dial indicator (B) and puller (C) [SST: ST30031000 (J-22912-01)]. And then calculate mean value.
1: Inner baulk ring
2: Synchronizer cone
Clearance "A"
Standard value: Refer to TM-75, "Baulk Ring Clearance". Baulk Ring Clearance
Limit value: Refer to TM-75, "Baulk Ring Clearance". Baulk Ring Clearance





2. Measure the clearance "B" at 2 points or more diagonally opposite using a feeler gauge (A). And then calculate mean value.
1: Outer baulk ring
2: Synchronizer cone
Clearance "B"
Standard value: Refer to TM-75, "Baulk Ring Clearance". Baulk Ring Clearance
Limit value: Refer to TM-75, "Baulk Ring Clearance". Baulk Ring Clearance

Baulk Ring Clearance for Triple Cone Synchronizer (3rd)





^ Check the clearance between outer baulk ring (1), synchronizer cone (2), and inner baulk ring (3) as follows.

CAUTION:
The clearances "A", "B" and "C" are controlled with outer baulk ring, synchronizer cone, and inner baulk ring as a set. Replace them as a set if the clearances are outside the limit value.





1. Measure the clearance "A" at 2 points or more diagonally opposite using a feeler gauge (B). when pressing outer baulk ring (1), synchronizer cone (2), and inner baulk ring (3) toward gear taper cone (C). And then calculate mean value.
Clearance "A"
Standard value: Refer to TM-75, "Baulk Ring Clearance". Baulk Ring Clearance
Limit value: Refer to TM-75, "Baulk Ring Clearance". Baulk Ring Clearance





2. Measure the clearance "B" at 2 points or more diagonally opposite using a feeler gauge (A). And then calculate mean value.
1: Outer baulk ring
2: Synchronizer cone
Clearance "B"
Standard value: Refer to TM-75, "Baulk Ring Clearance". Baulk Ring Clearance
Limit value: Refer to TM-75, "Baulk Ring Clearance". Baulk Ring Clearance





3. Measure the clearance "C" at 2 points or more diagonally opposite using a feeler gauge (A) when pressing outer baulk ring (1), synchronizer cone (2), and inner baulk ring (3) toward gear taper cone (B). And then calculate mean value.
Clearance "C"
Standard value: Refer to TM-75, "Baulk Ring Clearance". Baulk Ring Clearance
Limit value: Refer to TM-75, "Baulk Ring Clearance". Baulk Ring Clearance

BEARING





If the bearing does not rotate smoothly or the contact surface on ball or race is damaged or peeled, replace with new ones.