Mainshaft and Gears

DISASSEMBLY





1. Before disassembly, measure gear end play.
Gear end play: Refer to Manual Transmission/Transaxle; Specifications.
^ If end play is not within the specified limit, disassemble and check the parts.








2. Remove mainshaft rear bearing snap ring, C-ring holder and C-rings.





3. Remove mainshaft rear bearing and spacer.





4. Remove 5th main gear.





5. Remove 4th main gear, 4th gear bushing and steel ball.
^ Be careful not to lose steel ball.





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





7. Remove 2nd & 3rd bushing and 2nd gear.
^ Be careful not to lose the steel ball.





8. Remove 1st & 2nd synchronizer hub and 1st main gear.

INSPECTION
Gear and Shaft





^ Check shaft for cracks, wear or bending.
^ Check gears for excessive wear, chips or cracks.

Synchronizers





^ Check spline area of coupling sleeves, hubs and gears for wear or cracks.
^ Check baulk rings for cracks or deformation.
^ Check insert springs for deformation.





^ Measure clearance between baulk ring and gear.
Clearance between baulk rings and gears, for 1st and 4th gears: Refer to Manual Transmission/Transaxle; Specifications.
^ 2nd and 3rd gears have inner and outer baulk rings and so have different measurements.





^ Measure wear of 2nd and 3rd baulk ring.
a. Place baulk rings in position on synchronizer cone.
b. While holding baulk ring against synchronizer cone as far as it will go, measure dimensions "A" and "B".
Standard:
A: 0.7 - 0.9 mm (0.028 - 0.035 inch)
B: 0.6 - 1.1 mm (0.024 - 0.043 inch)
Wear limit: 0.2 mm (0.008 inch)
^ If dimension "A" or "B" is smaller than the wear limit, replace outer baulk ring, inner baulk ring and synchronizer cone as a set.

Bearing





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

ASSEMBLY





1. Install 1st gear needle bearing, 1st main gear and baulk ring.
2. Press on 1st & 2nd synchronizer hub.





^ Ensure correct fitting of 1st & 2nd synchronizer hub.





3. Install 2nd synchronizer cone, outer & inner baulk ring and 1st & 2nd coupling sleeve.





4. Install steel ball, 2nd main gear, 2nd & 3rd bushing.
^ Apply gear oil to 2nd 8 3rd gear bushing.
^ Apply multi-purpose grease to steel ball before installing it.
^ 2nd & 3rd bushing has a groove in which steel ball fits.





5. Install 3rd main gear, synchronizer cone, and outer & inner baulk ring.
6. Press on 3rd & 4th synchronizer hub.





7. Install 3rd & 4th coupling sleeve and 4th baulk ring.
^ Ensure correct fitting of 3rd 8 4th synchronizer hub.





8. Install steel ball, 4th bushing and 4th main gear.
^ Apply multi-purpose grease to steel ball before installing it.
^ 4th bushing has a groove in which steel ball fits.





9. Press on 5th main gear.








10. Install spacer and measure distance "C".
11. Select proper mainshaft bearing spacer to give correct standard length.
Standard length "C": 230.15 - 230.25 mm (9.0610 - 9.0649 inch)
Available spacers: Refer to Application and ID.





12. Press on mainshaft rear bearing.





13. Select proper mainshaft C-ring to minimize clearance of groove in mainshaft and install it.
Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 inch)
Mainshaft C-rings: Refer to Application and ID.





14. Install C-ring holder and snap ring.
15. Measure gear end play as a final check. Refer to "DISASSEMBLY".