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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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Standard: 0.02 mm (0.001 in.) max.
Service Limit: 0.05 mm (0.002 in.)
13-35
2. Inspect the runout by supporting both ends of the
mainshaft. Then rotate the mainshaft two complete
turns while measuring with a dial gauge. If the
runout exceeds the service limit, replace the
mainshaft.
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Exploded View
13-36Manual Transmission
Mainshaft Reassembly
5TH SYNCHRO SLEEVE
5TH SYNCHRO HUB TAPERED CONE RING
MBS DISTANCE COLLAR
NEEDLE BEARING
SYNCHRO RING
4TH/5TH GEAR DISTANCE COLLAR
SYNCHRO
SPRING
SYNCHRO SPRING ANGULAR BALL BEARING
SYNCHRO SPRING
MAINSHAFT SYNCHRO RING
3RD/4TH
SYNCHRO SLEEVE
3RD/4TH
SYNCHRO HUB
NEEDLE BEARING
4TH GEAR
SYNCHRO RING
3RD GEAR
SYNCHRO RING
5TH GEAR
SYNCHRO SPRING Note the direction of
installation.
Check for wear and operation. Check for wear and operation.
Note the direction
of installation.
Note the direction
of installation.
Note the direction
of installation.
Check for wear and operation.
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Special Tools Required
13-37
A D E
B
C A
B C
B
07746-0030100 A
Inner driver handle, 40 mm 07746-0030100
Inner bearing driver attachment, 30 mm07746-0030300
NOTE: Refer to the Exploded View, as needed, during
this procedure. 1. Clean all parts in solvent, dry them, and apply MTF to all contact surfaces.
2. Install the needle bearing (A) and 3rd gear (B) on the mainshaft (C).
3. Install the synchro ring (D) and the synchro spring (E). 4. Install the 3rd/4th synchro hub (A) by aligning the
synchro ring fingers (B) with the grooves (C) in the
3rd/4th synchro hub.
5. Press on the 3rd/4th synchro hub (A) using the 40 mm inner driver handle (B) and a press.
(cont’d)
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13-38Manual Transmission
Mainshaft Reassembly (cont’d)
B
A
A
D E
B
C B
C
A D
E
6. Install the 3rd/4th synchro sleeve (A) by aligning
the stops (B) of the 3rd/4th synchro sleeve and the
3rd/4th synchro hub. After installing, check the
operation of the 3rd/4th synchro hub set.
7. Install the synchro ring (A) with the synchro spring (B) by aligning the synchro ring fingers (C) with the
grooves (D) in the 3rd/4th synchro hub.
8. Install 4th gear (E) on to the synchro ring. 9. Install the 4th/5th gear distance collar (A) with the
needle bearings (B), then install 5th gear (C).
10. Install the synchro ring (D) with the synchro spring (E) onto 5th gear.
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13-39
B
C
A
B
07746-0030100 A C
07746-0030300 B
A
11. Install the 5th synchro hub (A) by aligning the
synchro ring fingers (B) with the grooves (C) in the
5th synchro hub.
12. Press on the 5th synchro hub (A) using the 40 mm inner driver handle (B), the 30 mm inner bearing
driver attachment (C), and a press. 13. Install the 5th synchro sleeve (A) by aligning the
slots of the 5th synchro sleeve and the 5th synchro
hub (B). After installing, check the operation of the
5th synchro hub set.
NOTE: Make sure to align the slots in the 5th
synchro hub as shown.
(cont’d)
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ÎÎ
13-40Manual Transmission
Mainshaft Reassembly (cont’d)
A
D E
B
C F
B
07746-0030100
C
07746-0030300
A
D
14. Install the synchro ring (A) with the synchro spring
(B) by aligning the synchro ring fingers (C) with the
grooves (D) in the 5th synchro hub.
15. Install the MBS distance collar (E) and the tapered cone ring (F). 16. Press on new angular ball bearing (A) using the
40 mm inner driver handle (B), 30 mm inner
bearing driver attachment (C), and a press (D).
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Standard: 0.06 0.16 mm (0.002 0.006 in.)
Service Limit: 0.25 mm (0.010 in.)
Standard: 23.03 23.08 mm (0.907 0.909 in.) Standard: 22.92 22.97 mm (0.902 0.904 in.)
Service Limit: 22.87 mm (0.900 in.)
Standard: 0.06 0.16 mm (0.002 0.006 in.)
Service Limit: 0.25 mm (0.010 in.)
13-41
Countershaft Assembly Clearance Inspection
C
BA
BA
C
1. Measure the clearance between 1st gear (A) and
the 1st gear distance collar (B) with a feeler gauge
(C).
If the clearance exceeds the service limit, go to step 2.
If the clearance is within the service limit, go to step 4.
2. Measure the length of the 1st gear distance collar as shown.
If the length is not within the standard, replace the 1st gear distance collar.
If the length is within the standard, go to step 3. 3. Measure the thickness of 1st gear.
If the thickness is less than the service limit,replace 1st gear.
If the thickness is within the service limit, replace the 1st/2nd synchro hub and the reverse gear as
aset.
4. Measure the clearance between 2nd gear (A) and 3rd gear (B) with a feeler gauge (C). If the clearance
exceedstheservicelimit,gotostep5.
(cont’d)
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