Page 2225 of 4555
INPUT SHAFT AND GEARS
MT-69
D
E
F
G
H
I
J
K
L
MA
B
MT
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 bearing
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.Clearance “B”
Standard value : 0.6 - 1.1 mm (0.024 - 0.043 in)
Limit value : 0.2 mm (0.008 in)
SCIA1084E
MTF0041D
SCIA0921E
PCIB0799E
Page 2226 of 4555
MT-70
INPUT SHAFT AND GEARS
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.
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.
SCIA1083E
SCIA0922E
PCIB0800E
Standard value for dimension C2
: 154.7 - 154.8 mm (6.091 - 6.094 in)
SCIA0925E
Page 2227 of 4555
INPUT SHAFT AND GEARS
MT-71
D
E
F
G
H
I
J
K
L
MA
B
MT
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-6th synchronizer hub, 5th-6th spread spring and 5th-
6th shifting insert onto 5th-6th coupling sleeve.
CAUTION:
Be careful with orientation of 5th-6th synchronizer hub.
Do not reuse 5th-6th synchronizer hub.
Be careful with orientation of 5th-6th coupling sleeve.
Do not reuse 5th-6th coupling sleeve.
Be sure not to hook center projection of 2 spread springs
on same shifting insert.
13. Press in 5th-6th synchronizer hub assembly using the press
stand.
CAUTION:
Align grooves of 5th-6th shifting insert and 5th baulk ring
and 6th baulk ring.
SCIA0926E
SCIA0921E
PCIB0801E
SCIA1083E
SCIA0928E
Page 2228 of 4555

MT-72
INPUT SHAFT AND GEARS
14. Install 6th needle bearing, 6th input gear, 6th baulk ring onto 6th
input gear bushing, and then press in 6th bushing onto input
shaft using the drift.
15. Install snap ring onto input shaft, and make sure that end play
(gap between snap ring and groove) of 6th input gear bushing
satisfies the standard value.
If measurement is outside the standard range, select snap
ring. Refer to MT-105, "
6TH INPUT GEAR BUSHING" .
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 6th 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, 5th and 6th input gears.
SCIA0969E
End play standard value : 0 - 0.1 mm (0 - 0.004 in)
SCIA0970E
SCIA0971E
PCIB0826E
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
Page 2229 of 4555
MAINSHAFT AND GEARS
MT-73
D
E
F
G
H
I
J
K
L
MA
B
MT
MAINSHAFT AND GEARSPFP:32241
Disassembly and Assembly (RS5F51A)ECS008C6
DISASSEMBLY
1. Before disassembling, measure the end play of 1st and 2nd
main gears.
2. Remove snap ring.
3. Remove C-ring holder, and then remove mainshaft C-ring.
4. Remove mainshaft rear bearing using the drift and pullers.
5. Remove snap ring.End play standard value
1st main gear : 0.20 - 0.30 mm (0.0079 - 0.0118 in)
2nd main gear : 0.06 - 0.16 mm (0.0024 - 0.0063 in)
SCIA0933E
PCIB0802E
SCIA0935E
SCIA0936E
Page 2230 of 4555
MT-74
MAINSHAFT AND GEARS
6. Press out 4th main gear and 5th main gear using the drift and a
puller.
7. Remove 4th main gear adjusting shim.
8. Remove 3rd-4th mainshaft spacer.
9. Press out 3rd main gear, 2nd main gear, 2nd needle bearing,
2nd main gear bushing, 1st-2nd synchronizer hub assembly, 1st
main gear, 1st needle bearing, and 1st main gear bushing
reverse main gear using the drift.
INSPECTION AFTER DISASSEMBLY
Mainshaft and Gears
Check items below. If necessary, replace them with new ones.
Damage, peeling, dent, uneven wear, bending, and other non-
standard conditions of the shaft.
Excessive wear, damage, peeling, and other non-standard con-
ditions of the gears.
Synchronizer
Check items below. If necessary, replace them with new ones.
Damage and unusual wear on contact surfaces of coupling
sleeve, synchronizer hub and shifting insert.
Coupling sleeve and synchronizer hub must move smoothly.
SCIA0937E
SCIA0938E
SCIA1075J
SMT387A
Page 2231 of 4555

MAINSHAFT AND GEARS
MT-75
D
E
F
G
H
I
J
K
L
MA
B
MT
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
Triple-cone synchronizer (1st and 2nd)
Check the clearance between outer baulk ring, synchronizer
cone and inner baulk ring as follows.
CAUTION:
The clearances “A”, “B” and “C” 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 feeler gauge when pressing baulk ring toward clutch
gear taper cone. 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.
SMT867D
PCIB1358E
Clearance “A”
Standard value : 0.6 - 1.2 mm (0.024 - 0.047 in)
Limit value : 0.3 mm (0.012 in)
PCIB1359E
Clearance “B”
Standard value : 0.6 - 1.1 mm (0.024 - 0.043 in)
Limit value : 0.2 mm (0.008 in)
PCIB1360E
Page 2232 of 4555
MT-76
MAINSHAFT AND GEARS
3. Measure the clearance “C” at 2 points or more diagonally oppo-
site using a feeler gauge when pressing baulk ring toward clutch
gear taper cone. And then calculate mean value.
Bearing
Check items below. If necessary, replace them with new ones.
Damage and rough rotation of bearing
ASSEMBLY
1. Press in reverse main gear using the drifts and the press stand.
CAUTION:
Be careful with orientation of reverse main gear.
Do not reuse reverse main gear.Clearance “C”
Standard value : 0.7 - 1.1 mm (0.028 - 0.043 in)
Limit value : 0.3 mm (0.012 in)
PCIB1361E
MTF0041D
SCIA0939E
SCIA0992E