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13-28Manual Transmission
Change Lever Assembly Disassembly/Reassembly
BREATHER CAP
6x1.0mm
12 N·m
(1.2 kgf·m, 9 lbf·ft)
ROLLER
WASHER
5TH SELECT
SPRING
SELECT STOP
PLATE SHIFT ARM
COVER
INTERLOCK REVERSE LOCK CAM
STRIKER8 mm SPRING WASHER
8mmSPECIALBOLT
31 N·m
(3.2 kgf·m, 23 lbf·ft)
DUST COVER CHANGE LEVER
CHANGE LEVER COVER
SELECT LEVER
DUST SEAL
1ST/2ND SELECT
SPRING SHIFT ARM
OIL SEAL
(P/N 08798-9002)
(P/N 08798-9002)
(P/N 08798-9002)
NOTE: Prior to reassembling, clean all the parts in solvent, dry them, and apply grease to the contact surfaces as
shown.
Turn toward the front of
the vehicle, then install it. Be careful not to damage the
dust seal when installing it.
Replace.
Replace.
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Standard: 0.35 0.65 mm (0.014 0.026 in.)
Service Limit: 1.0 mm (0.039 in.)
Standard: 7.4 7.6 mm (0.29 0.30 in.) Standard: 0.2 0.5 mm (0.008 0.020 in.)
Service Limit: 0.62 mm (0.024 in.)
Standard: 16.9 17.0 mm (0.665 0.669 in.)
13-29
Shift Fork Clearance Inspection
A
B
B
A
1. Measure the clearance between each shift fork (A) and its matching synchro sleeve (B). If the
clearance exceeds the service limit, go to step 2.
2. Measure the thickness of the shift fork fingers. If the thickness is not within the standard, replacethe shift fork.
If the thickness is within the standard, replace the synchro sleeve and the synchro hub as a set.
If one arm of the shift fork shows more wear than others, the fork may be bent and needs to be
replaced. 3. Measure the clearance between the shift fork (A)
and the shift arm (B). If the clearance exceeds the
service limit, go to step 4.
4. Measure the width of the shift arm. If the width is not within the standard, replace theshift arm.
If the width is within the standard, replace the shift fork and the reverse shift piece.
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13-30Manual Transmission
Shift Fork Disassembly/Reassembly
1ST/2ND
SHIFT FORK
5x25mmSPRINGPIN PIN DRIVER, 5 mm
3RD/4TH
SHIFT FORK
5TH SHIFT FORK
REVERSE SHIFT PIECE
NOTE: Prior to reassembling, clean all the parts in solvent, dry them, and apply MTF to all contact surfaces.
Replace.
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Standard: 0.06 0.16 mm (0.002 0.006 in.)
Service Limit: 0.25 mm (0.010 in.) Standard: 23.92 23.97 mm (0.942 0.944 in.)
Service Limit: 23.80 mm (0.937 in.)
Standard: 0.06 0.16 mm (0.002 0.006 in.)
Service Limit: 0.25 mm (0.010 in.)
13-31
Mainshaft Assembly Clearance Inspection
D
E
B
C
A
B
C
A
1. Support the bearing inner race with an appropriatesized socket (A), and push down on the
mainshaft (B).
2. Measure the clearance between 2nd gear (C) and 3rd gear (D) with a feeler gauge (E).
If the clearance exceeds the service limit, go to step 3.
If the clearance is within the service limit, go to step 4. 3. Measure the thickness of 3rd gear.
If the thickness is less than the service limit,replace 3rd gear.
If the thickness is within the service limit, replace the 3rd/4th synchro hub and the 3rd/4th synchro
sleeve as a set.
4. Measure the clearance between 4th gear (A) and the 4th/5th gear distance collar (B) with a dial
indicator (C).
If the clearance exceeds the service limit, go to step 5.
If the clearance is within the service limit, go to step 7.
(cont’d)
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Standard: 24.03 24.08 mm (0.946 0.948 in.)
Standard: 23.92 23.97 mm (0.942 0.944 in.)
Service Limit: 23.80 mm (0.937 in.)
Standard: 0.06 0.16 mm (0.002 0.006 in.)
Service Limit: 0.25 mm (0.010 in.)
Standard: 24.03 24.08 mm (0.946 0.948 in.)
13-32Manual Transmission
Mainshaft Assembly Clearance Inspection (cont’d)
A
C
B
5. Measure the length of the 4th/5th gear distancecollar as shown.
If the length is not within the standard, replace the 4th/5th gear distance collar.
If the length is within the standard, go to step 6.
6. Measure the thickness of 4th gear. If the thickness is less than the service limit,replace 4th gear.
If the thickness is within the service limit, replace the 3rd/4th synchro hub and the 3rd/4th synchro
sleeve as a set. 7. Measure the clearance between the 4th/5th gear
distance collar (A) and 5th gear (B) with a dial
indicator (C).
If the clearance exceeds the service limit, go to step 8.
If the clearance is within the service limit, go to step 10.
8. Measure the length of the 4th/5th gear distance collar as shown.
If the length is not within the standard, replace the 4th/5th gear distance collar.
If the length is within the standard, go to step 9.
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Standard: 23.92 23.97 mm (0.942 0.944 in.)
Service Limit: 23.80 mm (0.937 in.)
Standard: 23.95 24.05 mm (0.943 0.947 in.)
13-3313-33
Mainshaft Disassembly
C
B
A
A
B
9. Measure the thickness of 5th gear.
If the thickness is less than the service limit,replace 5th gear.
If the thickness is within the service limit, replace the 5th synchro hub and the 5th/6th synchro
sleeve as a set.
10. Measure the length of the MBS distance collar. If the length is not within standard, replace the
MBS distance collar. NOTE: Refer to the Exploded View in the Mainshaft
Reassembly, as needed, when removing components
pressed on to the mainshaft (see page 13-36).
1. Remove the angular ball bearing (A) and the tapered cone ring using a commercially available
bearing separator (B) and a commercially available
bearing puller (C). Make sure the bearing separator
is under the tapered cone ring.
2. Support 5th gear (A) on steel blo cks, and press the
mainshaft out of the 5th synchro hub (B) and 5th
gear.
NOTE: Do not use a jaw-type puller; it can damage
the gear teeth.
(cont’d)
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Standard: 23.92 23.97 mm (0.942 0.944 in.)
Service Limit: 23.80 mm (0.937 in.)
Standard: 23.95 24.05 mm (0.943 0.947 in.)
13-3313-33
Mainshaft Disassembly
C
B
A
A
B
9. Measure the thickness of 5th gear.
If the thickness is less than the service limit,replace 5th gear.
If the thickness is within the service limit, replace the 5th synchro hub and the 5th/6th synchro
sleeve as a set.
10. Measure the length of the MBS distance collar. If the length is not within standard, replace the
MBS distance collar. NOTE: Refer to the Exploded View in the Mainshaft
Reassembly, as needed, when removing components
pressed on to the mainshaft (see page 13-36).
1. Remove the angular ball bearing (A) and the tapered cone ring using a commercially available
bearing separator (B) and a commercially available
bearing puller (C). Make sure the bearing separator
is under the tapered cone ring.
2. Support 5th gear (A) on steel blo cks, and press the
mainshaft out of the 5th synchro hub (B) and 5th
gear.
NOTE: Do not use a jaw-type puller; it can damage
the gear teeth.
(cont’d)
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Standard:
A Ball Bearing Contact Area (transmission housing
side):27.987 28.000 mm (1.1018 1.1024 in.)
B 4th/5th Gear Distance Collar Contact Area: 31.984 32.000 mm (1.2592 1.2598 in.)
C Needle Bearing Contact Area: 38.984 39.000 mm (1.5348 1.5354 in.)
D Ball Bearing Contact Area (clutch housing side): 27.977 27.990 mm (1.1015 1.1020 in.)
E Bushing Contact Area: 20.80 20.85 mm (0.819 0.821 in.)
Service Limit:
A: 27.93 mm (1.100 in.)
B: 31.93 mm (1.257 in.)
C: 38.93 mm (1.533 in.)
D: 27.92 mm (1.099 in.)
E: 20.75 mm (0.817 in.)
13-3413-34 Manual Transmission
Mainshaft Disassembly (cont’d) Mainshaft Inspection
A
B
ED
CB
A
3. Support 3rd gear (A) on steel blocks, and press themainshaft out of the 3rd/4th synchro hub (B) and
3rd gear.
NOTE: Do not use a jaw-type puller; it can damage
the gear teeth. 1. Inspect the gear and bearing contact areas for wear
and damage, then measure the mainshaft at points
A, B, C, D, and E. If any part of the mainshaft is less
than the service limit, replace it.
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