Page 2217 of 4555
INPUT SHAFT AND GEARS
MT-61
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1. Measure the clearance “A” at 2 points or more diagonally oppo-
site using a dial indicator. And then calculate mean value.
2. Measure the clearance “B” at 2 points or more diagonally oppo-
site using a feeler gauge. And then calculate mean value.
Bearing
Check items below. If necessary, replace them with new ones.
Damage and rough rotation of bearingClearance “A”
Standard value : 0.6 - 0.8 mm (0.024 - 0.031 in)
Limit value : 0.2 mm (0.008 in)
SCIA0951E
Clearance “B”
Standard value : 0.6 - 1.1 mm (0.024 - 0.043 in)
Limit value : 0.2 mm (0.008 in)
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MTF0041D
Page 2218 of 4555
MT-62
INPUT SHAFT AND GEARS
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 3rd-4th synchronizer hub onto 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 outer baulk
ring.
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PCIB0799E
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SCIA0922E
Page 2219 of 4555
INPUT SHAFT AND GEARS
MT-63
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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-106, "
INPUT SHAFT THRUST WASHER" .
CAUTION:
Only one thrust washer can be selected.
9. Press in 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 5th synchronizer hub and 5th spread spring, 5th shifting insert onto 5th coupling sleeve.
PCIB0800E
Standard for dimension C2
: 154.7 - 154.8 mm (6.091 - 6.094 in)
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Page 2220 of 4555
MT-64
INPUT SHAFT AND GEARS
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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Page 2221 of 4555

INPUT SHAFT AND GEARS
MT-65
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14. Press in 5th stopper and then input shaft bearing spacer using
the drift.
15. Install snap ring onto input shaft, and make sure 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-105, "
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.
SCIA0929E
End play standard value : 0 - 0.1 mm (0 - 0.004 in)
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PCIB0825E
End play standard value
3rd input gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th input gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th input gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
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Page 2222 of 4555
MT-66
INPUT SHAFT AND GEARS
Disassembly and Assembly (RS6F51A)ECS008C5
DISASSEMBLY
1. Before disassembling, measure end play for 3rd, 4th, 5th and
6th input gears.
2. Remove oil channel.
3. Press out input shaft rear bearing using the drift and a puller.
4. Remove snap ring.
5. Press out 6th input gear, 6th needle bearing and 6th input gear
bushing using the drift and a puller.
6. Remove 6th baulk ring.
7. Press out 5th input gear and 5th-6th synchronizer hub assembly
using the drift and a puller.
8. Remove 5th needle bearing.End play standard value
3rd input gear : 0.18 - 0.31 mm (0.0071 - 0.0122 in)
4th input gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
5th input gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
6th input gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0966E
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Page 2223 of 4555
INPUT SHAFT AND GEARS
MT-67
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9. Press out 5th input gear bushing, thrust washer, 4th input gear,
4th needle bearing, 4th input gear bushing, 3rd-4th synchronizer
hub assembly and 3rd input gear using the drift and a puller.
10. Remove 3rd needle bearing.
11. 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
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.
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Page 2224 of 4555

MT-68
INPUT SHAFT AND GEARS
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
Single-cone synchronizer (4th, 5th and 6th)
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.
Double-cone synchronizer (3rd)
Check the clearance between outer baulk ring, synchronizer
cone and inner baulk ring as follows.
CAUTION:
The clearances “A” and “B” are controlled with outer baulk
ring, synchronizer cone and inner baulk ring as a set.
Replace them as a set if the clearances are outside the limit
value.
1. Measure the clearance “A” at 2 points or more diagonally oppo-
site using a dial indicator. And then calculate mean value.
SMT867D
Clearance
Standard value
4th : 0.9 - 1.45 mm (0.035 - 0.057 in)
5th and 6th : 0.95 - 1.4 mm (0.037 - 0.055 in)
Limit value : 0.7 mm (0.028 in)
SMT140
SCIA0950E
Clearance “A”
Standard value : 0.6 - 0.8 mm (0.024 - 0.031 in)
Limit value : 0.2 mm (0.008 in)
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