Page 1425 of 3189
SMT420CA
Measure wear of 1st and 2nd double baulk rings.
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 0.6 - 0.8 mm (0.024 - 0.031 in)
B 0.6 - 1.1 mm (0.024 - 0.043 in)
Wear limit:
0.2mm(0.008in)
c) If dimension “A” or “B” is smaller than the wear limit, replace
outer baulk ring, inner baulk ring and synchronizer cone as a
set.
SPD715
BearingNJMT0015S03Make sure bearings roll freely and are free from noise, cracks,
pitting or wear.
When replacing tapered roller bearing, replace outer and
inner race as a set.
SMT996B
ASSEMBLYNJMT0016
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REPAIR FOR COMPONENT PARTSRS5F50A
Mainshaft and Gears (Cont’d)
MT-105
Page 1426 of 3189

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:
0-0.1mm(0-0.004in)
Snap ring of 1st & 2nd synchronizer hub:
Refer to SDS, MT-133.
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-133.
REPAIR FOR COMPONENT PARTSRS5F50A
Mainshaft and Gears (Cont’d)
MT-106
Page 1427 of 3189

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-103.
SMT744AA
Final Drive
DISASSEMBLYNJMT00171. 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
INSPECTIONNJMT0018Gear, Washer, Shaft and CaseNJMT0018S01Check mating surfaces of differential case, viscous coupling,
side gears and pinion mate gears.
Check washers for wear.
SPD715
BearingsNJMT0018S03Make 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.
GI
MA
EM
LC
EC
FE
CL
AT
AX
SU
BR
ST
RS
BT
HA
SC
EL
IDX
REPAIR FOR COMPONENT PARTSRS5F50A
Mainshaft and Gears (Cont’d)
MT-107
Page 1428 of 3189
SMT062A
ASSEMBLYNJMT00191. 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-133.
SMT612AA
4. Install retaining pin.
Make sure that retaining pin is flush with case.
REPAIR FOR COMPONENT PARTSRS5F50A
Final Drive (Cont’d)
MT-108
Page 1429 of 3189
SMT609A
5. Install final gear.
6. Install speedometer drive gear.
SMT648
7. Press on differential side bearings.
SMT665C
Shift Control Components
INSPECTIONNJMT0020Check contact surface and sliding surface for wear, scratches,
projections or other damage.
SMT030A
Case Components
REMOVAL AND INSTALLATIONNJMT0021Input Shaft Oil SealNJMT0021S01
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REPAIR FOR COMPONENT PARTSRS5F50A
Final Drive (Cont’d)
MT-109
Page 1430 of 3189
SMT031A
Apply multi-purpose grease to seal lip of oil seal before
installing.
SMT034A
Mainshaft Front Bearing Outer RaceNJMT0021S02Extract the oil channel and remove the mainshaft front bear-
ing outer race.
Mainshaft Rear Bearing Outer RaceNJMT0021S03Refer to “Mainshaft Bearing Preload”, MT-134.
Differential Side Bearing Outer RaceNJMT0021S04Refer to “Input Shaft End Play and Differential Side Bearing
Preload”, MT-134.
REPAIR FOR COMPONENT PARTSRS5F50A
Case Components (Cont’d)
MT-110
Page 1431 of 3189

NJMT0022
Input Shaft End Play and Differential Side
Bearing Preload
NJMT0022S01If 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-92.
SMT074A
5. Using the following procedures, measure clearance between
bearings and transmission case.
DIFFERENTIAL SIDENJMT0022S01011. Attach dial indicator. If clamp diameter of dial indicator is too
small or too large, attach dial indicator using a magnetic stand.
GI
MA
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ADJUSTMENTRS5F50A
Input Shaft End Play and Differential Side Bearing Preload
MT-111
Page 1432 of 3189

SMT075AA
2. Insert Tool all the way into differential side gear. Move Tool up
and down and measure dial indicator deflection.
SMT076A
INPUTSHAFTSIDENJMT0022S01021. 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-136.
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-92.
Mainshaft Bearing PreloadNJMT0022S02If 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-112