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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.) Standard: 0.02 mm (0.001 in.) max.
Service Limit: 0.05 mm (0.002 in.)
13-112Manual Transmission
Mainshaft Inspection
E
D
CB
A
1. Inspect the gear and bearing contact areas for wearand 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. 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
13-113
Mainshaft Reassembly
4TH/5TH GEAR DISTANCE COLLARSYNCHRO
SPRING
SYNCHRO SPRING ANGULAR BALL BEARING
SYNCHRO SPRING
NEEDLE BEARING
MAINSHAFT
SYNCHRO SPRING
NEEDLE BEARING
SYNCHRO RING
SYNCHRO RING
3RD/4TH
SYNCHRO SLEEVE
3RD/4TH
SYNCHRO HUB
INNER RING* SYNCHRO RING*
SYNCHRO CONE*
NEEDLE BEARING 5TH/6TH SYNCHRO SLEEVE
5TH/6TH SYNCHRO HUB
5TH GEAR
4TH GEAR
SYNCHRO RING* INNER RING*
SYNCHRO CONE* 6TH GEAR
DISTANCE COLLAR
3RD GEAR 6TH GEAR
(cont’d)
Check for wear and operation.
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.
Check for wear and operation.
*: The components of the double cone synchro assembly.
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Special Tools Required
13-114 Manual Transmission
Mainshaft Reassembly (cont’d)
A
B
C
D
A
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 double cone synchro assembly (A) by aligning the synchro cone fingers (B) with the holes
(C) in 3rd gear, then install the synchro spring (D). 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.
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13-115
B A
D A
C B A
C
B
A D
E
B
C
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 double cone synchro assembly (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 (A) by aligning the synchro cone
fingers (B) with the holes (C) in 4th gear.
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.
(cont’d)
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13-116Manual Transmission
Mainshaft Reassembly (cont’d)
B
C
A
B
07746-0030100 A C
07746-0030300 A
B
11. Install the 5th/6th synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the
5th/6th synchro hub.
12. Press on the 5th/6th synchro hub (A) using the 40 mm inner driver handle (B) and the 30 mm inner
bearing driver attachment (C). 13. Install the 5th/6th synchro sleeve (A) by aligning
the slots of the 5th/6th synchro sleeve and the
5th/6th synchro hub (B). After installing, check the
operation of the 5th/6th synchro hub set.
NOTE: Make sure to align the slots in the 5th/6th
synchro hub as shown.
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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.)
13-11713-117
Countershaft Assembly Clearance
Inspection
A
D E
B
C F
G
B
07746-0030100
C
07746-0030300
A
D A
B
C
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/6th synchro hub.
15. Install the 6th gear distance collar (E) with the needle bearing (F), then install 6th gear (G).
16. Press on new angular ball bearing (A) using the 40 mm inner driver handle (B), the 30 mm inner
bearing driver attachment (C), and a press (D). 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.
(cont’d)
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13-119
Countershaft Disassembly
C D
B A D
B A
E
C
D
B A
E
C
NOTE: Refer to the Exploded View in the Countershaft
Reassembly, as needed, when removing components
pressed on to the countershaft (see page 13-121).
1. Securely clamp the countershaft assembly in a bench vise with wood blocks.
2. Remove the special bolt (left-hand threads).
3. Support 6th gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the
countershaft out of the ball bearing and 6th gear.
4. Remove the 35 mm shim. 5. Support 4th gear (A) on steel blocks (B), then use a
press (C) and an attachment (D) to press the
countershaft (E) out of 4th gear and 5th gear.
6. Support 2nd gear (A) on steel blocks (B), then use a press (C) and an attachment (D) to press the
countershaft (E) out of 2nd gear and 3rd gear.
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Standard:
A Ball Bearing Contact Area (Transmission
Housing Side):30.020 30.033 mm (1.1819 1.1824 in.)
B 1st Gear Distance Collar Contact Area: 39.937 39.950 mm (1.5723 1.5728 in.)
C Needle Bearing Contact Area (Clutch Housing Side):35.000 35.015 mm (1.3780 1.3785 in.)
Service Limit:
A: 29.97 mm (1.180 in.)
B: 39.883 mm (1.5702 in.)
C: 34.95 mm (1.376 in.) Standard: 0.02 mm (0.001 in.) max.
Service Limit: 0.05 mm (0.002 in.)
13-120Manual Transmission
Countershaft Inspection
C
B
A
1. Inspect the gear and bearing contact areas for wearand damage, then measure the countershaft at
points A, B, and C. If any part of the countershaft is
less than the service limit, replace it. 2. Inspect the runout by supporting both ends of the
countershaft. Then rotate the countershaft two
complete turns while measuring with a dial gauge.
If the runout exceeds the service limit, replace the
countershaft.
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