Part 1

DISASSEMBLY





1. Before removing transmission case, remove bolts and plugs as shown left.
2. Remove transmission case.





3. Remove position switch.





4. Mesh 4th gear, and then remove reverse idler shaft and reverse idler gear.





5. Pull out retaining pin.





6. Remove reverse lever spring and reverse lock spring from reverse lever assembly.





7. Remove reverse arm shaft while rotating it.





8. Remove reverse lever assembly.
- Be careful not to lose check ball.





9. Remove 5th & reverse check plug, spring and ball.





10. Remove stopper rings and retaining pins from 5th and 3rd & 4th fork rods.
11. Remove 5th and 3rd & 4th fork rods. Then remove forks and brackets.





12. Remove both input and mainshaft with 1st & 2nd fork and fork rod as a set.
13. Remove final drive assembly.
- Always withdraw mainshaft straight out. Failure to do so can damage resin oil channel on clutch housing side.





14. Remove reverse gate assembly.
- Be careful not to lose check ball.









15. Remove retaining pin and detach the selector.





16. Remove drain plug for convenience in removing retaining pin which holds striking lever to striking rod.





17. Remove retaining pin and then withdraw striking lever and striking rod.

INPUT SHAFT AND GEARS
DISASSEMBLY





1. Before disassembly, check 3rd, 4th and 5th input gear end plays.





Gear end play: Refer to image.





- If not within specification, disassemble and check contact surface of gear, shaft and hub. Check clearance of snap ring groove.





2. Remove input shaft rear bearing.





3. Remove 5th & reverse synchronizer and 5th input gear.





4. Remove thrust washer ring, 4th input gear thrust washers and 4th input gear.





5. Remove snap ring.





6. Remove 3rd & 4th synchronizer and 3rd input gear.





7. Remove input shaft front bearing.

INSPECTION





Gear And Shaft
- Check shaft for cracks, wear or bending.
- Check gears for excessive wear, chips or cracks.





Synchronizer
- Check spline portion of coupling sleeves, hubs and gears for wear or cracks.
- Check baulk rings for cracks or deformation.
- Check insert springs for wear or deformation.





- Measure clearance between baulk ring and gear (3rd, 4th and 5th).

Clearance between baulk ring and gear:
Standard 1.0 - 1.35 mm (0.0394 - 0.0531 inch)
Wear limit 0.7 mm (0.028 inch)





- Measure wear of reverse baulk ring.
a. Place reverse baulk ring on Tool and then place reverse synchronizer cone on reverse baulk ring.
- Make sure projection of synchronizer cone is positioned over the recess on Tool.
b. While holding reverse synchronizer cone against reverse baulk ring as firmly as possible, measure dimension "A" with dial indicator.

Wear limit:
Dimension "A" 1.2 mm (0.047 inch)

c. If dimension "A" is smaller than the wear limit, replace baulk ring.





Bearing
- Make sure bearings roll freely and are free from noise, cracks, pitting or wear.





ASSEMBLY





1. Place inserts in three grooves on coupling sleeve (3rd & 4th synchronizer).









2. Install 3rd input gear and 3rd baulk ring.
3. Press on 3rd & 4th synchronizer hub.
- Pay attention to its direction.
4. Select proper snap ring of 3rd & 4th synchronizer hub to minimize clearance of groove, and then install it.

Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 inch)





Snap ring of 3rd & 4th synchronizer hub: Refer to image.





5. Install 4th input gear.
6. Select proper thrust washers to minimize clearance of groove.
Then install them and thrust washer ring.

Allowable clearance of groove:
0 - 0.06 mm (0 - 0.0024 inch)





4th input gear thrust washer: Refer to image.





7. Install 5th & reverse synchronizer assembly.
a. Hook insert springs on reverse baulk ring.





b. Install insert springs with reverse baulk ring onto coupling sleeve.
- Pay attention to position of insert springs.
c. Place 5th baulk ring on 5th input gear.
d. Install reverse synchronizer cone on reverse baulk ring.





e. Place reverse synchronizer assembly on 5th input gear.
- Mesh recesses of 5th input gear with projections of reverse synchronizer cone.
- Put insert spring mounts on reverse baulk ring upon those on 5th baulk ring.





f. Press on 5th & reverse synchronizer assembly with 5th input gear.





8. Install input shaft front and rear bearings.
9. Measure gear end play as a final check.