Part 1

Mainshaft Disassembly, Inspection, and Reassembly

1. Inspect the thrust needle bearing and the, needle bearing for galling and rough movement.

Mainshaft:

2. Inspect the splines for excessive wear and damage.
3. Check the shaft bearing surface 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, the 40 x 63 mm thrust washer in the direction shown.
7. Replace the locknut and the conical spring washer with new ones when assembling the transmission.
8. Check the axial clearance of 3rd gear.

Mainshaft 3rd Gear Axial Clearance Inspection

1. Remove the mainshaft transmission housing bearing.
2. Install the thrust needle bearing (A), 3rd gear (B), the needle bearing (C), the thrust needle bearing (D), the 40 x 63 mm thrust washer (E), the 3rd/5th clutch (F) the 5th gear collar (G), and the transmission housing bearing (H) on the mainshaft (I). Do not install the O-rings during inspection.





3. Install the idler gear (J) on the mainshaft by a press, then install the conical spring washer (K) and the locknut (L).
4. Tighten the locknut to 29 N-m (3.0 kgf-m, 22 lbf-ft).
5. Set the dial indicator (A) on 3rd gear (B).





6. Lift 3rd gear (A) up while holding the mainshaft, and use the dial indicator (B) to read the 3rd gear axial clearance.





7. Measure the 3rd gear axial clearance in at least three places while moving 3rd gear. Use the average as the actual clearance.

Standard: 0.04 - 0.10 mm (0.002 - 0.004 in.)

8. If the clearance is out of standard, remove the 40 x 63 mm thrust washer and measure its thickness (A).





9. Select and install a new thrust washer, then recheck.





10. After replacing the thrust washer, make sure the clearance is within standard.
11. Disassemble the installed parts from the mainshaft.
12. Reinstall the bearing in the transmission housing.

Countershaft Disassembly, Inspection, and Reassembly

1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.

Countershaft:

2. Inspect the splines for excessive wear and damage.
3. Check the shaft bearing surface for scoring and excessive wear.
4. Lubricate all parts with ATF during assembly.
5. Install the conical spring washer, the park gear, the reverse selector, the 33 x 45 x 7.8 mm collar, and gears in the direction shown.
6. Replace the locknut and the conical spring washer with new ones when assembling the transmission. The countershaft locknut has left-hand threads.
7. Some reverse selector hubs are press-fitted to the countershaft; remove the hubs with a press, and install them with the special tool and a press.

Countershaft Reverse Selector Hub Removal

1. Remove the reverse selector hub from the countershaft by hand. If the reverse selector hub (A) cannot be removed by hand, it is press-fitted to the countershaft (B), and remove it from the countershaft with a press. Place 4th-5th gear (C) on press bases (D), and place a shaft protector (E) between the countershaft and press to prevent damaging the countershaft.





2. Support the bottom of the countershaft with one hand, then press the countershaft out of the press-fitted reverse selector hub, and remove the countershaft while holding the underside the countershaft. The countershaft will drop down after pressing it out of the press-fitted reverse selector hub.
3. Remove the remaining parts from the countershaft, if necessary.

Countershaft Reverse Selector Hub Installation

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

1. Install 1st gear, 2nd gear, 3rd gear, the 33.2 x 40 x 26 mm collar, the 29 mm cotters, and the 33 x 45 x 7.8 mm collar on the countershaft, and secure them with the snap ring.
2. Install the needle bearings and 4th-5th gear.
3. Slide the reverse selector hub (A) over the countershaft (B), then press it in place using the 40 mm I.D. driver and a press.





Secondary Shaft Disassembly, Inspection, and Reassembly

1. Inspect the thrust needle bearing and the needle bearing for galling and rough movement.

Secondary Shaft:

2. Inspect the splines for excessive wear and damage.
3. Check the shaft bearing surface 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, the idler gear, and the 31 x 54 mm thrust washer in the direction shown.
7. Replace the locknut and the conical spring washer with new ones when assembling the transmission. The locknut has left-hand threads.
8. Check the axial clearance of 1st gear and 2nd gear.
9. Inspect the condition of the sealing rings. If the sealing rings are worn, distorted, or damaged, replace them.

Secondary Shaft 1st Gear Axial Clearance Inspection

1. Install the thrust needle bearing (A), 1st gear (B), the needle bearing (C), the thrust needle bearing (D), the 31 x 54 mm thrust washer (E), and the 1st 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 1st clutch drum (B) using a feeler gauge (C), in at least three places. Use the average as the actual clearance.





3. If the clearance is out of standard, remove the 31 x 54 mm thrust washer and measure its thickness (A).





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 installed parts from the secondary shaft.

Secondary Shaft 2nd Gear Axial Clearance Inspection

1. Install the thrust needle bearing (A), the needle bearing (B), 2nd gear (C), the thrust needle bearing (D), the 43 x 54.5 mm thrust washer (E), the 39 mm cotters; (F) and the cotter retainer (G) on the secondary shaft (H), then secure them with the snap ring (I).





2. Set the dial indicator (A) on 2nd gear (B).





3. Lift 2nd gear (A) up while holding the secondary shaft (B), and use the dial indicator (C) to read the 2nd gear axial clearance.





4. Measure the 2nd gear axial clearance in at least three places while turning 2nd gear. Use the average as the actual clearance.

Standard: 0.04 - 0.12 mm (0.002 - 0.005 in.)

5. If the clearance is out of standard, remove the 43 x 54.5 mm thrust washer and measure its thickness.
6. Select and install a new thrust washer, then recheck.





7. After replacing the thrust washer, make sure the clearance is within standard.
8. Disassemble the installed parts from the secondary shaft.

Secondary Shaft Sealing Ring Replacement

The sealing rings are synthetic resin with chamfered ends. Check the condition of the sealing rings, and replace them only if they are worn, distorted, or damaged.

1. For a better fit, squeeze sealing rings together slightly before installing them.





2. Apply ATF to new sealing rings, then install them on the mainshaft.





3. After installing the sealing rings, check the following:

^ The rings are fully seated in the groove.
^ The rings are not twisted.
^ The chamfered ends of the rings are properly joined.