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MANUAL TRANSAXLE OVERHAUL
wear
Da
S Y N C H R O N I Z E R K E Y A N D
(1) for wear of key
(2) the spring for deform&i&
age.
SPEED GEARS
(1) Check the synchronizer cone for rough surface, damage
and wear.
(2) Check the gear bore and front and rear ends for damage
and wear.
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Page 938 of 2103
MANUAL TRANSAXLE OVERHAUL
Intermediate Gear ,
INTERMEDIATE GEAR 2220018004~
DISASSEMBLY AND REASSEMBLY
. .
‘I
7
8
7
Lubricate all internalparts with engine oil
during reassembly.
Disassembly steps
1. Snap ring
2. Taper roller bearing 9. Synchronizer key
3. Bearing sleeve 10. speed synchronizer hub
4.
speed gear 11. Synchronizer ring
12.
5. speed13.N e e d l e g e a r6.Needle bearing
Synchronizer ring bearing
7. Synchronizer spring 14. Taper roller bearing
8. speed synchronizer sleeve 15. Intermediate gear
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Page 939 of 2103
MANUAL TRANSAXLE.: OVERHAUL
Gear
.,
DISASSEMBLY AND REASSEMBLY
Disassembly steps
1. Snap ring2. Taper roller bearing Bearing sleeve4. speed gear5. Needle bearing6. Synchronizer ring7. Synchronizer spring8. speed synchronizer
9. Synchronizer key
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speed
11.12. Synchronizer cone 13. Synchronizer inner speed gear
15. Needle
16. Taper roller bearing 1 7 .
7
. . , ___
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MANUAL TRANSAXLE OVERHAUL
Intermediate Gear. .
DISASSEMBLY SERVICE POINTS
ROLLER BEARING SPEED GEAR
REMOVAL
2201053
2
3
Caution
lDo not reuse the bearing removed from the shaft.
lReplace the inner and outer races of the taper roller
bearing as a set.
SPEED SYNCHRONIZER HUB
SPEED GEAR REMOVAL
TAPER ROLLER BEARING REMOVAL
Caution
lDo not reuse the bearing removed from the shaft.
Replace the inner and outer races of the taper roll er
bearing as a set.
R E A S S E M B L Y S E R V I C E
ROLLER BEARING
Caution
When installing the bearing, push the inner race on ly.
,
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Page 941 of 2103
MANUAL TRANSAXLE OVERHAUL
bear
Identification mark RINGS
GEAR INSTALLATION .
The speed gear and of
r i n g s h a v e a n i d e n t i f i c a t i o n m a r k .
Clutch housing
Identification markTooth missing here
Synchronizer key
1 SPEED
SYNCHRONIZER KEY
SLEEVE
(1) the speed
as
(2) The synchronizer sleeve has tooth missing at si x portions.
Assemble the hub to the sleeve in such a way that t he
center tooth
between two missing teeth will touch
the synchronizer key.
SYNCHRONIZER SPRING INSTALLATION
When installing the synchronizer springs, be sure t o position
each spring with respect to the keys as illustrated.
BEARING SLEEVE INSTALLATION
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. .
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MANUAL TRANSAXLE OVERHAUL
Intermediate Gear.
TAPER ROLLER BEARING
Caution
When installing the bearing, push the. race only.
RING INSTALLATION,
Select and install the snap that gives
intermediate gear bearing end play.
Standard, value:
Intermediate gear bearing end
mm in.)
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Page 943 of 2103
MANUAL TRANSAXLE OVERHAUL
Gear
ring
201051
Gear2110009
and wear
Scratches and damage
and wear
I N S P E C T I O N
INTERMEDIATE GEAR
(1) Check the outer surface of the
the needle bearing is mounted’ abnormal
wear and seizure
(2) Check the splines for and
NEEDLE BEARING
(1) Combine the bearing or bearing’
sleeve and gear and check it rotates Smoothly without
abnormal noise or play.
(2) Check the needle bearing for’
SYNCHRONIZER RING
(1) Check the clutch gear teeth for damage breakage.
(2) Check the internal surface for damage,, broken
threads.
(3) Force the ring toward
check clearance “A”. if it is of specification.
Limit: 0.5 mm
in.)
SYNCHRONIZER OUTER RING, INNER RING AND CONE (1) Check that there are no scratches of damage on the
clutch gear teeth and cone surface.
(2) Check that there are no scratches, wear or peel ing on
the paper lining
Page 944 of 2103
MANUAL TRANSAXLE OVERHAUL
Intermediate Gear
the outer ring, inner ring and cone, and press them
onto the clutch gear. Check clearance and replace
if
is below the limit value..
Limit: 0.5 mm in.)
Replace the outer ring, inner ring cone, as
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SYNCHRONIZER SLEEVE AND HUB
(1) Combine the synchronizer
and hub and check
that they slide smoothly.
(2) Check that the sleeve is free from damage
its
front and rear ends.
(3) Check for wear of the end contact
each speed gear).
Caution
Replace the synchronizer hub and sleeve as a set.
SYNCHRONIZER KEY AND SPRING
(1)Check for wear of the protrusion.
(2) Check the spring for break-
age.
SPEED GEARS (1) Check the bevel gear and clutch gear teeth for damage
and wear.
(2) Check the synchronizer cone for damage
and wear.
(3) Check the gear bore and front arid rear ends fo r
and wear.