Page 2865 of 3051

SMT804BA
SMT472C
1. Press on 1st main gear, 1st synchronizer cone, inner & outer
baulk rings and 1st & 2nd synchronizer hub.
Refer to the illustration for step 3.
+Pay attention to direction of 1st & 2nd synchronizer hub.
2. Select proper snap ring of 1st & 2nd synchronizer hub to mini-
mize clearance of groove and then install it.
Allowable clearance of groove:
0 - 0.1 mm (0 - 0.004 in)
Snap ring of 1st & 2nd synchronizer hub:
Refer to SDS, MT-98.
SMT805B
3. Install 2nd synchronizer cone, inner & outer baulk rings. Insert
springs and 1st & 2nd coupling sleeve.
4. Install 2nd main gear.
+Ensure four protrusions of 2nd synchronizer cone are set in
holes of 2nd main gear.
SMT600CA
5. Press on 3rd main gear.
6. Press on 4th main gear.
SMT473CA
7. Press on 5th main gear.
8. Select proper snap ring of 5th main gear to minimize clearance
of groove and then install it.
Allowable clearance of groove:
0 - 0.15 mm (0 - 0.0059 in)
Snap ring of 5th main gear:
Refer to SDS, MT-98.
REPAIR FOR COMPONENT PARTSRS5F50A
Mainshaft and Gears (Cont’d)
MT-76
Page 2866 of 3051
SMT059A
9. Press on thrust washer and press on mainshaft rear bearing.
10. Press on mainshaft front bearing.
11. Measure gear end play as a final check. Refer to
“DISASSEMBLY”, MT-73.
SMT744AA
Final Drive
DISASSEMBLYNLMT00171. Remove final gear.
2. Remove speedometer drive gear by cutting it.
3. Press out differential side bearings.
+Be careful not to mix up the right and left bearings.
SMT612AA
4. Drive out retaining pin and draw out pinion mate shaft.
5. Remove pinion mate gears and side gears.
SMT083A
INSPECTIONNLMT0018Gear, Washer, Shaft and CaseNLMT0018S01+Check mating surfaces of differential case, side gears and
pinion mate gears.
+Check washers for wear.
SPD715
BearingsNLMT0018S03+Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
+When replacing taper roller bearing, replace outer and
inner race as a set.
REPAIR FOR COMPONENT PARTSRS5F50A
Mainshaft and Gears (Cont’d)
MT-77
Page 2867 of 3051
SMT062A
ASSEMBLYNLMT00191. Attach side gear thrust washers to side gears, then install pin-
ion mate washers and pinion mate gears in place.
SMT087A
2. Insert pinion mate shaft.
+When inserting, be careful not to damage pinion mate
thrust washers.
SMT610AH
3. Measure clearance between side gear and differential case
with washers following the procedure below:
a. Set Tool and dial indicator on side gear.
b. Move side gear up and down to measure dial indicator deflec-
tion. Always measure indicator deflection on both side gears.
Clearance between side gear and differential case with
washers:
0.1 - 0.2 mm (0.004 - 0.008 in)
SMT611A
c. If not within specification, adjust clearance by changing thick-
ness of side gear thrust washers.
Differential side gear thrust washer:
Refer to SDS, MT-98.
SMT612AA
4. Install retaining pin.
+Make sure that retaining pin is flush with case.
REPAIR FOR COMPONENT PARTSRS5F50A
Final Drive (Cont’d)
MT-78
Page 2868 of 3051
SMT609A
5. Install final gear.
6. Install speedometer drive gear.
SMT648
7. Press on differential side bearings.
SMT665C
Shift Control Components
INSPECTIONNLMT0020+Check contact surface and sliding surface for wear, scratches,
projections or other damage.
SMT030A
Case Components
REMOVAL AND INSTALLATIONNLMT0021Input Shaft Oil SealNLMT0021S01
REPAIR FOR COMPONENT PARTSRS5F50A
Final Drive (Cont’d)
MT-79
Page 2869 of 3051
SMT031A
+Apply multi-purpose grease to seal lip of oil seal before
installing.
SMT034A
Mainshaft Front Bearing Outer RaceNLMT0021S02+Extract the oil channel and remove the mainshaft front bear-
ing outer race.
Mainshaft Rear Bearing Outer RaceNLMT0021S03Refer to“Mainshaft Bearing Preload”, MT-99.
Differential Side Bearing Outer RaceNLMT0021S04Refer to“Input Shaft End Play and Differential Side Bearing
Preload”, MT-99.
REPAIR FOR COMPONENT PARTSRS5F50A
Case Components (Cont’d)
MT-80
Page 2870 of 3051

NLMT0022
Input Shaft End Play and Differential Side
Bearing Preload
NLMT0022S01If any of the following parts are replaced, adjust input shaft end
play.
+Input shaft
+Input shaft bearing
+Clutch housing
+Transmission case
If any of the following parts are replaced, adjust differential side
bearing preload.
+Differential case
+Differential side bearing
+Clutch housing
+Transmission case
SMT132AA
1. Remove differential side bearing outer race (transmission case
side) and shim(s).
SMT845B
2. Reinstall differential side bearing outer race without shim(s).
3. Install input shaft and final drive assembly on clutch housing.
4. Install transmission case without input shaft bearing shim(s).
Then tighten it to the specified torque.
Refer to“Case Components”, MT-62.
SMT074A
5. Using the following procedures, measure clearance between
bearings and transmission case.
DIFFERENTIAL SIDENLMT0022S01011. Attach dial indicator. If clamp diameter of dial indicator is too
small or too large, attach dial indicator using a magnetic stand.
ADJUSTMENTRS5F50A
Input Shaft End Play and Differential Side Bearing Preload
MT-81
Page 2871 of 3051

SMT075AA
2. Insert Tool all the way into differential side gear. Move Tool up
and down and measure dial indicator deflection.
SMT076A
INPUT SHAFT SIDENLMT0022S01021. Set dial indicator on end of input shaft.
2. Move input shaft up and down and measure dial indicator
deflection.
3. Select shims with proper thickness with SDS table as a guide.
Refer to SDS, MT-101.
4. Install selected differential side bearing adjusting shim and dif-
ferential side bearing outer race.
SMT475C
5. Check differential side bearing turning torque.
a. Install final drive assembly on clutch housing.
b. Install transmission case on clutch housing.
+Tighten transmission case fixing bolts to the specified
torque. Refer to“Case Components”, MT-62.
Mainshaft Bearing PreloadNLMT0022S02If any of the following parts are replaced, adjust mainshaft bearing
preload.
+Mainshaft
+Mainshaft bearings
+Clutch housing
+Transmission case
SMT077AA
1. Remove mainshaft rear bearing outer race and shim(s).
ADJUSTMENTRS5F50A
Input Shaft End Play and Differential Side Bearing Preload (Cont’d)
MT-82
Page 2872 of 3051

SMT644AA
2. Reinstall mainshaft rear bearing outer race without shims.
3. Clean mating surfaces of clutch housing and transmission
case with solvent.
4. Install mainshaft and mainshaft front bearing outer race into
transmission case. Turn mainshaft while holding bearing outer
race so that bearings are properly seated.
SMT078A
SMT079A
5. Put straightedge [width must be more than 50 mm (1.97 in)] on
transmission case, and measure the distance from upper sur-
face of straightedge to surface of the bearing outer race using
a depth micrometer.
+Measure at three places on bearing outer race, and take
the average.
6. Determine dimension A to be used by the following equation.
Dimension A = Width of straightedge measured dis-
tance
7. Measure the distance from mating surface of clutch housing to
portion with which mainshaft front bearing outer race is to be
mated.
+Measure at three places on the portion, and take the aver-
age.
Dimension B = Measured distance
8. Determine dimension C to be used by the following equation.
Dimension “C”=B A
9. Determine total thickness of shims with SDS table as a guide.
Mainshaft bearing adjusting shim:
Refer to SDS, MT-99.
10. Install selected mainshaft bearing adjusting shim and main-
shaft bearing outer race.
11. Check total turning torque after assembly—Refer to
“ASSEMBLY”, MT-84.
ADJUSTMENTRS5F50A
Mainshaft Bearing Preload (Cont’d)
MT-83