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TRANSAXLE ASSEMBLY
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REVERSE IDLER GEAR END PLAY
When adjusting reverse idler gear end play, select adjusting
shim for reverse idler gear. To select adjusting shim, measure
clearance between transaxle case and reverse idler gear. Refer
to MT-102, "
REVERSE IDLER GEAR ADJUSTING SHIM" .
CAUTION:
Only 1 adjusting shim can be selected.
Calculate dimension "Q" (thickness of adjusting shim) using the
following procedure to satisfy specification of end play for
reverse idler gear.
1. Using depth micrometer and straightedge, measure dimension
"Q
1 " between transaxle case end face and mounting face of
adjusting shim.
2. Using depth micrometer and straightedge as shown in the fig-
ure, measure dimension "Q
2 " between clutch housing end face
and end face of reverse idler gear (Rear).
3. Install selected reverse idler gear adjusting shim onto reverse
idler gear assembly.End play: 0.04 - 0.10 mm (0.0016 - 0.0039 in)
Dimension“Q” = (Q
1 - Q2 ) - End play
Q: Thickness of adjusting shim
Q
1 : Distance between transaxle case end face and
mounting face of adjusting shim
Q
2 : Distance between clutch housing end face and
end face of reverse idler gear (Rear)
PCIB0796E
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PCIB0797E
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MT-54
INPUT SHAFT AND GEARS
INPUT SHAFT AND GEARSPFP:32200
Assembly and Disassembly (RS5F51A)ECS008C4
DISASSEMBLY
1. Before disassembling, measure end play for 3rd, 4th, and 5th
input gears.
2. Remove oil channel.
3. Press out input shaft rear bearing using the drift and a puller.
4. Remove the snap ring.
5. Press out input shaft bearing spacer and 5th stopper using the
drift and a puller.End play standard value
3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
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INPUT SHAFT AND GEARS
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6. Press out 5th input gear and 5th synchronizer hub assembly
using the drift and a puller.
7. Remove 5th needle bearing.
8. Press out 5th input gear bushing, thrust washer, 4th input gear,
4th needle bearing, 4th input gear bushing, 4th baulk ring, 3rd-
4th synchronizer hub assembly, 3rd baulk ring and 3rd input
gear using the drift and a puller.
9. Remove 3rd needle bearing.
10. Press out input shaft front bearing using a puller.
INSPECTION AFTER DISASSEMBLY
Input Shaft and Gears
Check items below. If necessary, replace them with new ones.
Damage, peeling, dent, uneven wear, bending, etc. of shaft
Excessive wear, damage, peeling, etc. of gears
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MT-56
INPUT SHAFT AND GEARS
Synchronizer
Check items below. If necessary, replace them with new ones.
Damage and excessive wear of contact surfaces of coupling
sleeve, synchronizer hub, and shifting insert
Coupling sleeve and synchronizer hub must move smoothly.
If any crack, damage, or excessive wear is found on cam face of
baulk ring or working face of insert, replace it.
Baulk ring clearance
Push baulk ring on the cone, and measure the clearance
between baulk ring and cone. If measurement is below limit,
replace it with a new one.
Bearing
Check items below. If necessary, replace them with new ones.
Damage and rough rotation of bearing
SMT387A
SMT867D
Clearance
Standard value
3rd and 4th : 0.9 - 1.45 mm (0.035 - 0.057 in)
5th : 0.95 - 1.4 mm (0.037 - 0.055 in)
Limit value : 0.7 mm (0.028 in)
SMT140
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INPUT SHAFT AND GEARS
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ASSEMBLY
1. Install 3rd needle bearing to input shaft.
2. Install 3rd input gear and 3rd baulk ring to input shaft.
3. Install 3rd-4th spread spring, 3rd-4th shifting insert and a new 3rd-4th synchronizer hub onto a new 3rd-
4th coupling sleeve.
CAUTION:
Be careful with orientation of 3rd-4th synchronizer hub.
Do not reuse 3rd-4th synchronizer hub.
Be careful with orientation of 3rd-4th coupling sleeve.
Do not reuse 3rd-4th coupling sleeve.
Be sure not to hook center projection of 2 spread springs
on same shifting insert.
4. Press in 3rd-4th synchronizer hub assembly using the press
stand.
CAUTION:
Align grooves of 3rd-4th shifting insert and 3rd baulk ring.
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MT-58
INPUT SHAFT AND GEARS
5. Press in 4th input gear bushing using the press stand.
6. Install 4th baulk ring.
7. Install 4th needle bearing and 4th input gear to input shaft.
8. Select thrust washer so that dimension “C2” satisfies the stan-
dard value below. Then install thrust washer onto input shaft.
Refer to MT-101, "
INPUT SHAFT THRUST WASHER" .
CAUTION:
Only one thrust washer can be selected.
9. Press in a new 5th input gear bushing using the press stand.
CAUTION:
Do not reuse 5th input gear bushing.
10. Install 5th needle bearing and 5th input gear to input shaft.
11. Install 5th baulk ring.
12. Install a new 5th synchronizer hub and 5th spread spring, 5th shifting insert onto a new 5th coupling
sleeve.
PCIB0800E
Standard for dimension C2
: 154.7 - 154.8 mm (6.091 - 6.094 in)
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INPUT SHAFT AND GEARS
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CAUTION:
Be careful with orientation of 5th synchronizer hub and
shifting insert.
Do not reuse 5th synchronizer hub.
Be careful with orientation of 5th coupling sleeve.
Do not reuse 5th coupling sleeve.
Be sure not to hook center projection of 2 spread springs
on same shifting insert.
13. Press in 5th synchronizer hub assembly using the press stand.
CAUTION:
Align grooves of 5th shifting insert and 5th baulk ring.
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MT-60
INPUT SHAFT AND GEARS
14. Press in 5th stopper and then input shaft bearing spacer using
the drift.
15. Install a new snap ring onto input shaft, and check that end play
(gap between snap ring and groove) of input shaft bearing
spacer satisfies the standard value.
If measurement is outside the standard range, select snap
ring. Refer to MT-100, "
INPUT SHAFT BEARING SPACER" .
CAUTION:
Do not reuse snap ring.
16. Press in input shaft rear bearing using the drift.
CAUTION:
Install input shaft rear bearing with its brown surface facing
the input gear side.
17. Press in input shaft front bearing using the drifts.
18. Install oil channel onto input shaft.
19. Check end play of 3rd, 4th, and 5th input gears.
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End play standard value : 0 - 0.1 mm (0 - 0.004 in)
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End play standard value
3rd gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
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