Page 681 of 1503
Shift Fork Assembly
Disassembly/Reassembly
NOTE: Install the spring pins so their grooves are 180° apart.
Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces.
Disassembly: Remove the 3 mm spring pin and 5 mm spring pin.
Reassembly: Install the 5 mm spring pin first, then install the 3 mm spring pin.ProCarManuals.com
Page 682 of 1503
Mainshaft Assembl y
Index
NOTE : Th e 3rd/4t h an d 5th/6t h synchr o hub s ar e installe d wit h a press .
Prio r t o reassembling , clea n al l th e part s i n solvent , dr y them , an d appl y lubrican t t o an y contac t surfaces .
Th e 3rd/4t h an d 5th/6t h synchr o hubs , however , shoul d b e installe d wit h a pres s befor e lubricatin g them .
OUTE R SYNCHR O RIN GInspection , pag e 13-4 1
3RD/4T H SYNCHR O SLEEV E
Inspection , pag e 13-4 0
OUTE R SYNCHR O RIN G
Inspection , pag e 13-4 1
3RD GEARMeasurement , pag e 13-3 0
MAINSHAF T
Inspection , pag e 13-3 3
4TH GEA RMeasurement , pag e 13-3 0
SPACE R COLLA R'Inspection , pag e 13-30 , 13-3 1
5TH GEA RMeasurement , pag e 13-3 1
SYNCHR
O RIN G
Inspection , pag e 13-4 1
5TH/6T
H SYNCHR O SLEEV E
Inspection , pag e 13-4 0
SYNCHR
O RIN G
Inspection , pag e 13-4 1
6TH GEA RInspection , pag e 13-3 1
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Page 683 of 1503

Mainshaft Assembly
Clearance Inspection
1. Measure the clearance between 2nd and 3rd gears.
Standard: 0.06 - 0.19 mm
(0.002 - 0.007 in)
Service Limit: 0.3 mm (0.012 in)
3. Measure the clearance between 4th gear and the
spacer collar.
Standard: 0.06 - 0.19 mm
(0.002 - 0.007 in)
Service Limit: 0.3 mm (0.012 in)
2. If the
clearance exceeds
the
service
limit,
measure
the thickness of 3rd gear.
If the
thickness
of 3rd
gear
is
less than
the
service
limit,
replace 3rd gear with a new one.
If the thickness of 3rd gear is within the service limit,
replace the 3rd/4th synchro hub with a new one.
If the thickness of 4th gear is less than the service
limit, replace 4th gear with a new one.
If the thickness of 4th gear is within the service
limit, replace the 3rd/4th synchro hub with a new
one.
4. If the clearance exceeds the service limit, measure
on the spacer collar.
5. If is
less than
the
service
limit,
replace
the spacer collar with a new one.
If is within the service limit, measure
the thickness of 4th gear.ProCarManuals.com
Page 684 of 1503

6. Measure the clearance between the spacer collar
and 5th gear.
9. Measure the clearance between the distance collar
and 6th gear.
10. If the clearance exceeds the service limit, measure
on the distance collar.
11. If is less than the service limit, replace
the distance collar with a new one.
If is within the service limit, measure
thickness of 5th gear.
If the thickness of 6th gear is less than the service
limit, replace 6th gear with a new one.
If the thickness of 6th gear is within the service limit,
replace the 5th/6th synchro hub with a new one.
If the thickness of 5th gear is less than the service
limit, replace 5th gear with a new one.
If the thickness of 5th gear is within the service limit,
replace the 5th/6th synchro hub with a new one.
8. If is less than the service limit, replace
the spacer collar with a new one.
If is within the service limit, measure
thickness of 5th gear.
7. If the clearance exceeds the service limit, measure
on the spacer collar.ProCarManuals.com
Page 685 of 1503
Mainshaft Assembly
Disassembly
1. Support ball bearing on steel blocks as shown, and
press the shaft out of the ball bearing. Use of a jaw-
type puller can damage the gear teeth.
3. Support 5th gear on steel blocks as shown, and
press the shaft out of the 5th/6th synchro hub.
4. In the same manner as above, support the 3rd gear
on steel blocks, and press the shaft out of the 3rd/4th
synchro hub.
2. Support 6th gear on steel blocks as shown, and
press the shaft out of the ball bearing.ProCarManuals.com
Page 686 of 1503
If an y par t o f th e mainshaf t i s les s tha n th e servic e
limit , replac e th e mainshaf t wit h a ne w one . I
f th e runou t exceed s th e servic e limit , replac e
the mainshaf t wit h a ne w one .
Inspectio n
1. Inspec t th e gea r surfac e an d bearin g surfac e fo r
wea r an d damage , the n measur e th e mainshaf t a t
point s A , B , an d C . 2
. Suppor t th e mainshaf t a t bot h ends , an d inspec t fo r
runout .
Mainshaft Assembly
ProCarManuals.com
Page 687 of 1503

Mainshaft Assembl y
Reassembl y
CAUTION:
• Prio r t o reassembling , clea n al l th e part s i n solvent ,
dr y them , an d appl y lubrican t t o an y contac t parts .
• Pres s th e 3rd/4t h an d 5th/6t h synchr o hub s o n th e
mainshaf t withou t lubrication .
• Whe n installin g th e 3rd/4t h an d 5th/6t h synchr o
hubs , suppor t th e shaf t o n stee l blocks , an d instal l
th e synchr o hub s usin g a press .
• Instal l th e 3rd/4t h an d 5th/6t h synchr o hub s wit h a
maximu m pressur e o f 1,00 0 k g (2,20 5 Ibs) , the n pres s
bot h th e 3rd/4t h an d 5th/6t h synchr o hub s wit h a
pressur e o f 2,00 0 k g (4,40 9 Ibs) .
• Th e clutc h housin g bal l bearin g i s installe d whe n it' s
tim e t o chec k th e mainshaf t clearances .
NOTE : T o reassemble , se e pag e 13-31 .
1 . Suppor t 2n d gea r o n stee l blocks , the n instal l th e
3rd/4t h synchr o hu b usin g a press .
2 . Instal l th e 3rd/4t h synchr o sleev e b y alignin g th e
stop s o n th e 3rd/4t h synchr o sleev e an d hub . Afte r
installing , chec k th e operatio n o f th e 3rd/4t h syn -
chr o hu b set . 3
. Instal l th e 5th/6t h synchr o hu b usin g a press .
4 . Instal l th e transmissio n housin g sid e bal l bearin g
wit h th e tapere d en d facin g dow n usin g a press .
ProCarManuals.com
Page 688 of 1503
OUTER SYNCHR O RIN G
Inspection , pag e 13-4 1
SPACE R COLLA RSelection , pag e 13-3 6
1ST/2N D SYNCHR O SLEEV E
Inspection , pag e 13-4 0
COUNTERSHAF T.Inspection, pag e 13-3 8
THRUS T WASHE RSelection , pag e 13-3 6
OUTE
R SYNCHR O RIN G
Inspection , pag e 13-4 1
Countershaf t Assembl y
Index
NOTE : Th e 3rd , 4th , 5t h an d 6t h gear s ar e installe d wit h a press .
Prior t o reassembling , clea n al l th e part s in solvent , dr y them , an d appl y lubrican t t o an y contac t surfaces .The 3rd , 4th , 5t h an d 6t h gear s shoul d b e installe d withou t lubricatio n usin g a press .
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