Inspection

1. INSPECT SYNCHRONIZER RING

(a) Check for wear or damage.

(b) Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.

If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together. NOTICE:

Ensure the fine lapping compound is completely washed off after rubbing.

(c) Check again the braking effect of the synchronizer ring.

(d) Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end. Minimum clearance: 3r<l gear: 0.65 mm (0.0256 in.) 4th gear: 0.75 mm (0.0295 in.) if the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on gear cone. NOTICE:

Ensure the fine lapping compound is completely washed off after rubbing.

2. INSPECT GEAR SHIFT FORK AND HUB SLEEVE CLEARANCE

Using a feeler gauge, measure the clearance between the hub sleeve and gear shift fork.

Maximum clearance: 0.35 mm (0.014 in.) If the clearance exceeds the maximum, replace the gear shift fork or hub sleeve.

ÎXJ0331

3. INSPECT INPUT SHAFT

(a) Check the input shaft for wear or damage.

(b) Using a micrometer, measure the outer diameter of the input shaft journal surface-

Minimum outer diameter: Part A: 21.991 mm (0.8658 In.) Part 8: 24.885 mm (0.9797 in.) Part C: 28.985 mm (1.1411 in.) Part D: 30.985 mm (1.2199 in.) Part E: 24.985 mm (0.9837 in.) !f the outer diameter is iess than the minimum, replace the input shaft.

(c) Using a dial indicator, check the shaft runout. Maximum runout: 0.03 mm (0.0012 in.)

If the runout exceeds the maximum, replace the input shaft.

REASSEMBLY

HiNT:

Coat all of the sliding and rotating surfaces with gear oil before reassembly.

1. ASSEMBLE NO. 2 HUB SLEEVE ASSEMBLY

(a) Install the 3 No. 2 shifting key springs and No. 2 shifting keys to the No. 2 clutch hub.

(b) Install the No. 2 hub sleeve to the No. 2 clutch hub. NOTICE:

Assemble the No. 2 hub sleeve and No. 2 clutch hub in the direction shown in the illustration.

2. INSTALL NEEDLE ROLLER BEARING, 3RD GEAR, NO. 2 SYNCHRONIZER RING (FOR 3RD GEAR) AND NO. 2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT

(a) Apply gear oil to the needle roller bearings and install it.

(b) Install the 3rd gear and No, 2 synchronizer ring (for the 3rd gear).

NOTICE:

Distinguish the No. 2 synchronizer ring (for the 3rd gear) by the teeth on the synchronizer ring.

(c) install the No. 2 hub sleeve assembly so that the No. 2 synchronizer ring slots and No. 2 shifting keys are aligned.

NOTICE;

Be sure to install the No. 2 hub sleeve assembly In the correct direction, as shown in the illustration.

(d) Using a press, install the No. 2 hub sleeve assembly.

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3. INSTALL SNAP RING

(a) Select a snap ring from the table below that will make the thrust clearance of the No. 2 clutch hub less than 0.1 mm (0.0039 in.).

3. INSTALL SNAP RING

(a) Select a snap ring from the table below that will make the thrust clearance of the No. 2 clutch hub less than 0.1 mm (0.0039 in.).

Mark

Thickness mm (in.)

Mark

Ttîickness mm (in.)

0

2.30 (0 0906)

3

2.48 (0.0976)

1

2.36 (0.0929)

4

2.54(0.1000)

2

2.42 (0.0953)

5

2.60 (0.1024)

(b) Using a screwdriver and hammer, tap in the snap ring. HINT:

Take care not to damage the journal surface of the input shaft. 4. INSPECT 3RD GEAR THRUST CLEARANCE (See page MX-30)

(b) Using a screwdriver and hammer, tap in the snap ring. HINT:

Take care not to damage the journal surface of the input shaft. 4. INSPECT 3RD GEAR THRUST CLEARANCE (See page MX-30)

INSTALL SPACER, NEEDLE ROLLER BEARING, NO. 2 SYNCHRONIZER RING (FOR 4TH GEAR), 4TH GEAR AND CENTER RADIAL BALL BEARING

Install the spacer.

Apply gear oil to the needle roller bearings and install it. Place the No. 2 synchronizer ring (for the 4th gear) on the No. 2 hub sleeve assembly and align the No. 2 synchronizer ring slots with the No. 2 shifting keys. Install the 4th gear. NOTICE;

Distinguish the No. 2 synchronizer ring (tor the 4th gear) by the teeth on the synchronizer ring.

(e) Using SST and a press, install the center radial ball bearing.

S ST 09608-00071 NOTICE:

Be sure to install the center radial ball bearing in the correct direction, as shown in the illustration.

HINT:

Set SST to the bearing inner race securely.

6. INSTALL SNAP RING

(a) Select a snap ring from the table below that will make the thrust clearance of the center radial ball bearing less than 0.1 mm (0.0039 in.).

6. INSTALL SNAP RING

(a) Select a snap ring from the table below that will make the thrust clearance of the center radial ball bearing less than 0.1 mm (0.0039 in.).

Mark

Thickness mm (in.)

Mark

Thickness mm (in.)

A

2.29 (0.090?)

O

2.47 (0.0972)

8

2.35(0.0925)

6

2.53(0.0996)

C

2.41 (0.0949)

F

2.59 (0.1020)

(b) Using a screwdriver and hammer, tap in the snap ring. HiNT:

Take care not to damage the journal surface of the input shaft. 7. INSPECT 4TH GEAR THRUST CLEARANCE (See page MX-30)

(b) Using a screwdriver and hammer, tap in the snap ring. HiNT:

Take care not to damage the journal surface of the input shaft. 7. INSPECT 4TH GEAR THRUST CLEARANCE (See page MX-30)

Do It Yourself Car Diagnosis

Do It Yourself Car Diagnosis

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