Counter Gear And Reverse Idler Gear Removal

Install the 5th gear thrust washer lock ball, 5th gear thrust washer and 5th gear to the counter gear.

Using a dial indicator, measure the 5th gear radial clearance.

Standard clearance:

0.008 to 0.034 mm (0.0003 to 0.0013 in.)

1. If the clearance is not as specified, replace the 5th gear bearing.
   

Remove the 5th gear bearing from the 5th gear.

Using a snap ring expander, remove the snap ring from the 5th gear.

Remove the No. 3 hub sleeve, 2 No. 3 synchromesh shifting keys, key spring (return spring) and key spring (C spring) from the 5th gear.

Coat the No. 5 gear spline piece cone with gear oil. Check the braking effect of the No. 3 synchronizer ring. Fit the ring to the shaft cone. Apply pressure to the ring and attempt to turn it in both directions. Check that the ring locks.

1. If the braking effect is insufficient, apply a small amount of fine lapping compound between the No. 3 synchronizer ring and the No. 5 gear spline piece cone. Lightly rub the No. 3 synchronizer ring and No. 5 gear spline piece cone.
   

NOTICE:

Ensure the fine lapping compound is completely washed off after rubbing.

Check the braking effect of the No. 3 synchronizer ring again.

Using a feeler gauge, measure the clearance between the No. 3 synchronizer ring back and the No. 5 gear spline piece cone.

Standard clearance:

0.65 to 1.35 mm (0.0256 to 0.0531 in.)

1. If the clearance is not as specified, replace the No. 3 synchronizer ring, and apply a small amount of fine lapping compound on the No. 5 gear spline piece cone.
   

NOTICE:

Ensure the fine lapping compound is completely washed off after rubbing.

Check the sliding condition between the No. 3 hub sleeve and center shaft 5th gear.

Check that the spline gear's edges of the No. 3 hub sleeve are not worn down.

Using a vernier caliper, measure the No. 3 hub sleeve and No. 3 gear shift fork as shown in the illustration.

Standard clearance:

0.25 to 0.45 mm (0.0098 to 0.0177 in.)

1. If the clearance is not as specified, replace the No. 3 hub sleeve and No. 3 gear shift fork.
   

Using a cylinder gauge, measure the inside diameter of the 5th gear.

Standard inside diameter:

33.015 to 33.040 mm (1.2998 to 1.3008 in.)

Maximum inside diameter:

33.040 mm (1.3008 in.)

1. If the inside diameter is greater than the maximum, replace the 5th gear.
   

Using a micrometer, measure the outside diameter of the journal surface.

Standard outside diameter:

25.984 to 26.000 mm (1.0230 to 1.0236 in.)

Minimum outside diameter:

25.984 mm (1.0230 in.)

1. If the outside diameter is less than the minimum, replace the counter gear.
   

Make sure the front bearing rotates smoothly.

1. If the bearing does not rotate smoothly, replace the bearing.
   

Using a snap ring expander, remove the No. 2 counter gear front bearing snap ring from the counter gear.

Using SST, a press and 14 mm socket wrench, remove the counter gear front bearing from the counter gear.

SST

09515-10010