Перед разборкой раздаточной коробки в сборе тщательно очистите ее от посторонних веществ. Это предотвратит попадание в узел грязи при его разборке и последующей сборке.

При снятии деталей из легких сплавов, например крышки раздаточной коробки, не используйте такие инструменты, как отвертка, которые могут повредить их. Применяйте молоток с пластмассовым покрытием.

Обязательно раскладывайте снятые детали в том порядке, в котором они были сняты, и защитите их от попадания посторонних частиц.

Перед установкой каждой детали тщательно очистите и высушите ее. Затем нанесите на нее масло для раздаточной коробки. Не используйте щелочные химикаты для очистки алюминиевых и резиновых деталей или установочных болтов зубчатого венца. Кроме того, запрещается применять не оставляющий осадка растворитель и другие бензины химической чистки для очистки резиновых деталей, кольцевых уплотнений и сальников.

Покрывайте поверхности скольжения и вращающиеся детали гипоидным маслом.

Не зажимайте детали непосредственно в тисках. Прокладывайте между тисками и деталью алюминиевые губки.

Замените все поврежденные или деформированные пружинные стопорные кольца новыми.

Не допускайте образования царапин на сопрягающихся поверхностях картера. Это может привести к утечке масла.

С помощью лезвия бритвы и скребка для удаления остатков прокладок удалите остатки герметика FIPG с поверхности уплотнения.

Полностью очистите все детали от герметика FIPG.

Для очистки поверхностей уплотнения следует использовать растворитель, не оставляющий на них следов.

Нанесите вдоль поверхности уплотнения герметик FIPG в виде сплошного валика диаметром примерно 1,2 мм (0,0472 дюйма).

Установите детали в течение 10 минут после нанесения FIPG. В противном случае герметик FIPG придется удалить и нанести повторно.

Не допускайте попадания масла на уплотнение в течение, по крайней мере, 1 часа после уплотнения деталей.

Не допускайте образования царапин на поверхностях, вступающих в контакт с сальниками и прокладками. Это может привести к утечке масла.

При запрессовке сальника соблюдайте осторожность, чтобы не повредить кромку сальника и его боковую поверхность.

Using SST and a press, install a new radial ball bearing (inner race) to the counter gear.

• SST
• 09316-60011(09316-00041)
  09950-60010(09951-00540)

Select a new snap ring that will allow minimal axial play.

• Standard clearance:
• 0.1 mm (0.00394 in.) or less

• Standard Snap Ring:

• Part No.	Mark	Thickness
  90520-31015	A	2.35 to 2.40 mm (0.0925 to 0.0945 in.)
  90520-31016	B	2.40 to 2.45 mm (0.0945 to 0.0965 in.)
  90520-31017	C	2.45 to 2.50 mm (0.0965 to 0.0984 in.)
  90520-31018	D	2.50 to 2.55 mm (0.0984 to 0.1004 in.)
  90520-31019	E	2.55 to 2.60 mm (0.1004 to 0.1024 in.)
  90520-31020	F	2.60 to 2.65 mm (0.1024 to 0.1043 in.)
  90520-31021	G	2.65 to 2.70 mm (0.1043 to 0.1063 in.)
  90520-31022	H	2.70 to 2.75 mm (0.1063 to 0.1083 in.)
  90520-31023	J	2.75 to 2.80 mm (0.1083 to 0.1102 in.)
  90520-31024	K	2.80 to 2.85 mm (0.1102 to 0.1122 in.)
  90520-31025	L	2.85 to 2.90 mm (0.1122 to 0.1142 in.)
  90520-31033	M	2.90 to 2.95 mm (0.1142 to 0.1161 in.)

Using a snap ring expander, install the snap ring to the counter gear.

Apply a light coat of gear oil to the sleeve and hub.

Install the clutch hub to the clutch hub sleeve.

Install one of the balls to each shifting key.

Install one of the springs to each shifting key.

Install the shifting keys with balls and springs to the No. 1 clutch hub.

• ПРИМЕЧАНИЕ:

• Be careful to prevent the balls from flying off.

Coat the 2nd gear needle roller bearing with gear oil, and then install it to the counter gear.

Coat the counter shaft 2nd speed gear with gear oil, and then install it to the counter gear.

Coat the No. 1 synchronizer ring set with gear oil, and then install it to the counter gear.

Using SST and a press, install the No. 1 transmission clutch hub to the counter gear.

• SST
• 09316-60011

• УКАЗАНИЕ:

• Align the groove of the clutch hub with the protrusion of the synchronizer ring.

Check that the gear and synchronizer ring move smoothly.

Select a new snap ring that will allow minimal axial play.

• Standard clearance:
• 0.1 mm (0.00394 in.) or less

• Standard Snap Ring:

• Part No.	Mark	Thickness
  90520-45013	A	2.28 to 2.33 mm (0.0898 to 0.0917 in.)
  90520-45014	B	2.33 to 2.38 mm (0.0917 to 0.0937 in.)
  90520-45015	C	2.38 to 2.43 mm (0.0937 to 0.0957 in.)
  90520-45016	D	2.43 to 2.48 mm (0.0957 to 0.0976 in.)
  90520-45017	E	2.48 to 2.53 mm (0.0976 to 0.0996 in.)
  90520-45018	F	2.53 to 2.58 mm (0.0996 to 0.1016 in.)
  90520-45019	G	2.58 to 2.63 mm (0.1016 to 0.1035 in.)

Using a snap ring expander, install the snap ring to the counter gear.

Coat the No. 1 synchronizer ring set with gear oil, and then install it to the counter gear.

Coat the 1st gear needle roller bearing with gear oil, and then install it to the counter gear.

Coat the counter shaft 1st speed gear with gear oil and install it to the counter gear.

Using SST and a press, install the reverse gear spline piece.

• SST
• 09309-37010

Install the ball to the counter gear.

Coat the No. 4 synchronizer ring with gear oil and install it to the counter gear.

Coat the reverse gear needle roller bearing with gear oil and install it to the counter gear.

Install the key spring and 2 shifting keys to the reverse gear.

• УКАЗАНИЕ:

Install the hub sleeve to the reverse gear.

Coat the countershaft reverse gear with gear oil, and then install it to the counter gear.

Align the groove of the reverse gear bearing race inner with the ball and install the reverse gear bearing race inner.

Using SST and a press, install the counter gear front bearing or roller to the counter gear.

• SST
• 09608-06041

• УКАЗАНИЕ:

• Make sure that the groove of the bearing faces the correct direction as shown in the illustration.

Select a new snap ring that will allow minimal axial play.

• Standard clearance:
• 0.1 mm (0.00394 in.) or less

• Standard Snap Ring:

• Part No.	Mark	Thickness
  90520-31015	A	2.35 to 2.40 mm (0.0925 to 0.0945 in.)
  90520-31016	B	2.40 to 2.45 mm (0.0945 to 0.0965 in.)
  90520-31017	C	2.45 to 2.50 mm (0.0965 to 0.0984 in.)
  90520-31018	D	2.50 to 2.55 mm (0.0984 to 0.1004 in.)
  90520-31019	E	2.55 to 2.60 mm (0.1004 to 0.1024 in.)
  90520-31020	F	2.60 to 2.65 mm (0.1024 to 0.1043 in.)
  90520-31021	G	2.65 to 2.70 mm (0.1043 to 0.1063 in.)
  90520-31022	H	2.70 to 2.75 mm (0.1063 to 0.1083 in.)
  90520-31023	J	2.75 to 2.80 mm (0.1083 to 0.1102 in.)
  90520-31024	K	2.80 to 2.85 mm (0.1102 to 0.1122 in.)
  90520-31025	L	2.85 to 2.90 mm (0.1122 to 0.1142 in.)
  0520-31033	M	2.90 to 2.95 mm (0.1142 to 0.1161 in.)

Using a snap ring expander, install the snap ring to the counter gear.

Using a feeler gauge, measure the reverse gear thrust clearance.

• Standard clearance:
• 0.125 to 0.375 mm (0.00493 to 0.0148 in.)

If the clearance is outside the specification, replace the gear, spline piece or bearing race.

• УКАЗАНИЕ:

• Replace the part or parts determined to be the most likely cause of the problem.

Using a dial indicator, measure the 1st gear thrust clearance.

• Standard clearance:
• 0.10 to 0.43 mm (0.00394 to 0.0169 in.)

If the clearance is outside the specification, replace the gear, clutch hub, spline piece or counter gear.

• УКАЗАНИЕ:

• Replace the part or parts determined to be the most likely cause of the problem.

Using a dial indicator, measure the 2nd gear thrust clearance.

• Standard clearance:
• 0.10 to 0.43 mm (0.00394 to 0.0169 in.)

If the clearance is outside the specification, replace the gear, clutch hub or counter gear.

• УКАЗАНИЕ:

• Replace the part or parts determined to be the most likely cause of the problem.

Using a dial indicator, measure the reverse gear radial clearance.

• Standard clearance:
• 0.015 to 0.065 mm (0.000591 to 0.00255 in.)

If the clearance is outside the specification, replace the reverse gear needle roller bearing or shaft.

• УКАЗАНИЕ:

• Replace the part or parts determined to be the most likely cause of the problem.

Using a dial indicator, measure the 1st gear radial clearance.

• Standard clearance:
• 0.015 to 0.067 mm (0.000591 to 0.00263 in.)

If the clearance is outside the specification, replace the 1st gear needle roller bearing or shaft.

• УКАЗАНИЕ:

• Replace the part or parts determined to be the most likely cause of the problem.

Using a dial indicator, measure the 2nd gear radial clearance.

• Standard clearance:
• 0.015 to 0.067 mm (0.000591 to 0.00263 in.)

If the clearance is outside the specification, replace the 2nd gear needle roller bearing or shaft.

Using a dial indicator and 2 V-blocks, measure the shaft runout.

• Maximum runout:
• 0.03 mm (0.00118 in.)

If the runout is more than the maximum, replace the counter gear.

Using a micrometer, measure the journal diameter of each input shaft journal, at the specified positions.

• Standard Journal Diameter:

• Item	Specified Condition
  Journal A	34.002 to 34.015 (1.3387 to 1.3392)
  Journal B	36.985 to 37.000 (1.4561 to 1.4567)
  Journal C	47.985 to 48.000 (1.8892 to 1.8898)
  Journal D	53.985 to 54.000 (2.1254 to 2.1260)
  Journal E	34.002 to 34.015 (1.3387 to 1.3392)

• Minimum Journal Diameter:

• Item	Specified Condition
  Journal A	34.002 (1.3387)
  Journal B	36.985 (1.4561)
  Journal C	47.985 (1.8892)
  Journal D	53.985 (2.1254)
  Journal E	34.002 (1.3387)

If the journal diameter is less than the minimum, replace the counter gear shaft.

Using a cylinder gauge, measure the inside diameter of the reverse gear.

• Standard inside diameter:
• 51.015 to 51.040 mm (2.0085 to 2.0095 in.)

• Maximum inside diameter:
• 51.040 mm (2.0095 in.)

If the inside diameter is more than the maximum, replace the reverse gear.

Using a cylinder gauge, measure the inside diameter of the 1st gear.

• Standard inside diameter:
• 54.015 to 54.040 mm (2.1266 to 2.1276 in.)

• Maximum inside diameter:
• 54.040 mm (2.1276 in.)

If the inside diameter is more than the maximum, replace the 1st gear.

Using a cylinder gauge, measure the inside diameter of the 2nd gear.

• Standard inside diameter:
• 60.015 to 60.040 mm (2.3628 to 2.3638 in.)

• Maximum inside diameter:
• 60.040 mm (2.3638 in.)

If the inside diameter is more than the maximum, replace the 2nd gear.

Using a vernier caliper, measure the width of the No. 3 transmission hub sleeve groove (A) and the thickness of the claw part of the gear shift fork No. 4 (B), and calculate the clearance.

• Standard clearance (A - B):
• 0.26 to 0.84 mm (0.0102 to 0.0331 in.)

If the clearance is outside the specification, replace the No. 3 transmission hub sleeve and No. 4 gear shift fork.

Check the sliding condition between the No. 1 transmission hub and No. 1 transmission hub sleeve.

Check that the splines of the No. 1 transmission hub sleeve are not worn.

Using a vernier caliper, measure the width of the No. 1 transmission hub sleeve groove (A) and the thickness of the claw part of the No. 1 gear shift fork (B), and calculate the clearance.

• Standard clearance (A - B):
• 0.15 to 0.35 mm (0.00591 to 0.0138 in.)

If the clearance is outside the specification, replace the No. 1 transmission hub sleeve and No. 1 gear shift fork.

Using a feeler gauge, measure the clearance between the synchronizer ring and reverse gear.

• Standard clearance:
• 0.70 to 1.50 mm (0.0276 to 0.0590 in.)

• Minimum clearance:
• 0.70 mm (0.0276 in.)

If the clearance is less than the minimum, replace the synchronizer ring.

Coat the reverse gear cone with gear oil.

Check the braking effect of the synchronizer ring.

Using a feeler gauge, measure the clearance between the synchronizer ring and 1st gear.

• Standard clearance:
• Inner:
• 1.48 to 2.12 mm (0.0583 to 0.0835 in.)
• Middle:
• 0.68 to 1.92 mm (0.0268 to 0.0756 in.)
• Outer:
• 0.88 to 1.72 mm (0.0346 to 0.0677 in.)

• Minimum clearance:
• Inner:
• 1.48 mm (0.0583 in.)
• Middle:
• 0.68 mm (0.0268 in.)
• Outer:
• 0.88 mm (0.0346 in.)

• Text in Illustration

  *1	Middle
  *2	Outer
  *3	Inner

If the clearance is less than the minimum, replace the synchronizer ring.

Coat the 1st gear cone with gear oil.

Check the braking effect of the synchronizer ring.

Using a feeler gauge, measure the clearance between the synchronizer ring and 2nd gear.

• Standard clearance:
• Inner:
• 1.48 to 2.12 mm (0.0583 to 0.0835 in.)
• Middle:
• 0.68 to 1.92 mm (0.0268 to 0.0756 in.)
• Outer:
• 0.88 to 1.72 mm (0.0346 to 0.0677 in.)

• Minimum clearance:
• Inner:
• 1.48 mm (0.0583 in.)
• Middle:
• 0.68 mm (0.0268 in.)
• Outer:
• 0.88 mm (0.0346 in.)

• Text in Illustration

  *1	Middle
  *2	Outer
  *3	Inner

If the clearance is less than the minimum, replace the synchronizer ring.

Coat the 2nd gear cone with gear oil.

Check the braking effect of the synchronizer ring.

Using a feeler gauge, measure the reverse gear thrust clearance.

• Standard clearance:
• 0.125 to 0.375 mm (0.00493 to 0.0148 in.)

If the clearance is outside the specification, replace the gear, spline piece or bearing race.

• УКАЗАНИЕ:

• Replace the part or parts determined to be the most likely cause of the problem.

Using a dial indicator, measure the 1st gear thrust clearance.

• Standard clearance:
• 0.10 to 0.43 mm (0.00394 to 0.0169 in.)

If the clearance is outside the specification, replace the gear, clutch hub, spline piece or counter gear.

• УКАЗАНИЕ:

• Replace the part or parts determined to be the most likely cause of the problem.

Using a dial indicator, measure the 2nd gear thrust clearance.

• Standard clearance:
• 0.10 to 0.43 mm (0.00394 to 0.0169 in.)

If the clearance is outside the specification, replace the gear, clutch hub or counter gear.

• УКАЗАНИЕ:

• Replace the part or parts determined to be the most likely cause of the problem.

Using a dial indicator, measure the reverse gear radial clearance.

• Standard clearance:
• 0.015 to 0.065 mm (0.000591 to 0.00255 in.)

If the clearance is outside the specification, replace the reverse gear needle roller bearing or shaft.

• УКАЗАНИЕ:

• Replace the part or parts determined to be the most likely cause of the problem.

Using a dial indicator, measure the 1st gear radial clearance.

• Standard clearance:
• 0.015 to 0.067 mm (0.000591 to 0.00263 in.)

If the clearance is outside the specification, replace the 1st gear needle roller bearing or shaft.

• УКАЗАНИЕ:

• Replace the part or parts determined to be the most likely cause of the problem.

Using a dial indicator, measure the 2nd gear radial clearance.

• Standard clearance:
• 0.015 to 0.067 mm (0.000591 to 0.00263 in.)

If the clearance is outside the specification, replace the 2nd gear needle roller bearing or shaft.

Using a snap ring expander, remove the snap ring from the counter gear.

Using SST and a press, remove the counter gear front bearing or roller from the counter gear.

• SST
• 09950-00020
  09950-70010(09951-07100)
  09950-60010(09951-00320)

Remove the reverse gear bearing race inner from the counter gear.

Remove the counter shaft reverse gear from the counter gear.

Remove the hub sleeve, 2 shifting keys and key spring from the counter shaft reverse gear.

Remove the reverse gear needle roller bearing from the counter gear.

Remove the No. 4 synchronizer ring from the counter gear.

Remove the ball from the counter gear.

Using SST and a press, remove the counter shaft gear 1st speed together with the reverse gear spline piece from the counter gear.

• SST
• 09950-00020

Remove the 1st gear needle roller bearing from the counter gear.

Remove the No. 1 synchronizer ring set from the counter gear.

Using a snap ring expander, remove the snap ring from the counter gear.

Using SST and a press, remove the counter shaft 2nd speed gear together with the No. 1 transmission clutch hub from the counter gear.

• SST
• 09950-00020

Remove the 2nd gear needle roller bearing from the counter gear.

Remove the No. 1 synchronizer ring set from the 2nd gear.

Remove the hub sleeve, 3 synchromesh shifting keys, 3 balls and 3 springs from the clutch hub.

• УКАЗАНИЕ:

• Use a piece of cloth to prevent the balls and springs from flying off.

Using a snap ring expander, remove the snap ring from the counter gear.

Using SST and a press, remove the radial ball bearing (inner race) from the counter gear.

• SST
• 09950-00020

Using SST and a press, install a new output shaft rear bearing to the output shaft.

• SST
• 09316-60011(09316-00011)

Apply a light coat of MP grease to the bearing.

Apply gear grease to the output shaft center bearing and install it to the output shaft.

Apply gear oil to the No. 3 synchronizer ring and install it to the output shaft.

Using a cylinder gauge, measure the inside diameter of the output shaft.

• Standard inside diameter:
• 45.017 to 45.025 mm (1.7723 to 1.7726 in.)

• Maximum inside diameter:
• 45.025 mm (1.7726 in.)

If the diameter is more than the maximum, replace the output shaft.

Using a feeler gauge, measure the clearance between the synchronizer ring and gear spline.

• Standard clearance:
• 0.70 to 1.36 mm (0.0276 to 0.0535 in.)

• Minimum clearance:
• 0.70 mm (0.0276 in.)

If the clearance is less than the minimum, replace the synchronizer ring.

Coat the output shaft cone with gear oil.

Check the braking effect of the synchronizer ring.