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

• SST
• 09515-10010

Select a snap ring that will allow minimal axial play.

• Standard clearance:
• 0.1 mm (0.00393 in.) or less

• Standard No. 2 Counter Gear Front Bearing Snap Ring:

• Mark	Thickness
  1	2.05 to 2.10 mm (0.0807 to 0.0827 in.)
  2	2.10 to 2.15 mm (0.0827 to 0.0847 in.)
  3	2.15 to 2.20 mm (0.0847 to 0.0866 in.)
  4	2.20 to 2.25 mm (0.0866 to 0.0886 in.)
  5	2.25 to 2.30 mm (0.0886 to 0.0906 in.)
  6	2.30 to 2.35 mm (0.0906 to 0.0925 in.)

Using a snap ring expander, install the snap ring.

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.)

Check that the front bearing rotates smoothly.

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

Coat the needle roller bearing with gear oil and install it to the output shaft.

Coat the 3rd gear with gear oil and install it to the output shaft.

Coat the No. 1 synchronizer ring with gear oil and install it to the 3rd gear.

Coat the hub sleeve with gear oil and install it to the clutch hub.

Text in Illustration

Front

• ПРИМЕЧАНИЕ:

• Be sure to install the hub sleeve to the clutch hub in the correct direction.

Install the 3 synchromesh shifting keys to the clutch hub with the 2 synchromesh shifting key springs.

• ПРИМЕЧАНИЕ:

• Do not set both openings of the shifting key springs in the same position.

Using SST and a press, install the No. 2 clutch hub to the output shaft.

• SST
• 09316-60011(09316-00021)

Select a clutch hub shaft snap ring that will allow minimal axial play.

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

• Standard Clutch Hub Shaft Snap Ring:

• Mark	Thickness
  C-1	1.75 to 1.80 mm (0.0689 to 0.0709 in.)
  D	1.80 to 1.85 mm (0.0709 to 0.0728 in.)
  D-1	1.85 to 1.90 mm (0.0728 to 0.0748 in.)
  E	1.90 to 1.95 mm (0.0748 to 0.0768 in.)
  E-1	1.95 to 2.00 mm (0.0768 to 0.0787 in.)
  F	2.00 to 2.05 mm (0.0787 to 0.0807 in.)
  F-1	2.05 to 2.10 mm (0.0807 to 0.0827 in.)

Using a snap ring expander, install the snap ring.

Using a feeler gauge, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Coat the needle roller bearing with gear oil and install it to the output shaft.

Coat the 2nd gear with gear oil and install it to the output shaft.

Coat the No. 2 synchronizer ring with gear oil and install it to the 2nd gear.

Coat the reverse gear with gear oil and install it to the clutch hub.

Text in Illustration

Front

• ПРИМЕЧАНИЕ:

• Be sure to install the reverse gear to the clutch hub in the correct direction.

Install the 3 synchromesh shifting keys to the clutch hub with the 2 synchromesh shifting key springs.

• ПРИМЕЧАНИЕ:

• Do not set both openings of the shifting key springs in the same position.

Using SST and a press, install the clutch hub to the output shaft.

• SST
• 09316-60011

Coat the synchronizer ring with gear oil and install it to the No. 1 clutch hub.

Coat the lock ball with gear oil and install it to the output shaft.

Coat the needle roller bearing with gear oil.

Install the inner race and needle roller bearing to the 1st gear.

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

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

• SST
• 09316-60011(09316-00021)

Using a dial indicator, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Using SST and a press, install the 5th gear to the output shaft.

• SST
• 09316-60011(09316-00021)

Select a snap ring that will allow minimal axial play.

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

• Standard Output Shaft Bearing Shaft Snap Ring:

• Mark	Thickness
  A	2.67 to 2.72 mm (0.1052 to 0.1070 in.)
  B	2.73 to 2.78 mm (0.1075 to 0.1094 in.)
  C	2.79 to 2.84 mm (0.1099 to 0.1118 in.)
  D	2.85 to 2.90 mm (0.1123 to 0.1141 in.)
  E	2.91 to 2.96 mm (0.1146 to 0.1165 in.)
  F	2.97 to 3.02 mm (0.1170 to 0.1188 in.)
  G	3.03 to 3.08 mm (0.1193 to 0.1212 in.)
  H	3.09 to 3.14 mm (0.1217 to 0.1236 in.)
  J	3.15 to 3.20 mm (0.1241 to 0.1259 in.)
  K	3.21 to 3.26 mm (0.1264 to 0.1283 in.)
  L	3.27 to 3.32 mm (0.1288 to 0.1307 in.)

Using a brass bar and hammer, tap on the snap ring.

Using a dial indicator, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.30 mm (0.00394 to 0.0118 in.)

Using a feeler gauge, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Using a dial indicator, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Using a dial indicator, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Using a dial indicator, measure the radial clearance.

• Standard clearance:
• 0.008 to 0.034 mm (0.000315 to 0.00133 in.)

Using a dial indicator, measure the radial clearance.

• Standard clearance:
• 0.008 to 0.034 mm (0.000315 to 0.00133 in.)

Using a dial indicator, measure the radial clearance.

• Standard clearance:
• 0.009 to 0.056 mm (0.000355 to 0.00220 in.)

Using a micrometer, measure the journal diameter of the output shaft journal surface.

• Standard Journal diameter:

• Item	Specified Condition
  Journal A	34.984 to 35.000 mm (1.3774 to 1.3779 in.)
  Journal B	37.984 to 38.000 mm (1.4955 to 1.4960 in.)
  Journal C	30.384 to 30.400 mm (1.1963 to 1.1968 in.)

Using a micrometer, measure the flange thickness.

• Standard thickness:
• 4.80 to 5.20 mm (0.189 to 0.204 in.)

• Minimum thickness:
• 4.80 mm (0.189 in.)

Using a micrometer, measure the inner race thickness.

• Standard thickness:
• 3.995 to 4.195 mm (0.158 to 0.165 in.)

• Minimum thickness:
• 3.995 mm (0.158 in.)

Using a micrometer, measure the outside diameter of the inner race.

• Standard outside diameter:
• 38.985 to 39.000 mm (1.5349 to 1.5354 in.)

• Minimum outside diameter:
• 38.985 mm (1.5349 in.)

Coat the 1st gear cone with gear oil.

Check the braking effect of the No. 1 synchronizer ring.

Using a feeler gauge, measure the clearance between the No. 1 synchronizer ring back and 1st gear spline end.

• Standard clearance:
• 1.00 to 2.00 mm (0.0394 to 0.0787 in.)

Coat the 2nd gear cone with gear oil.

Check the braking effect of the No. 1 synchronizer ring.

Using a feeler gauge, measure the clearance between the No. 1 synchronizer ring back and 2nd gear spline end.

• Standard clearance:
• 1.00 to 2.00 mm (0.0394 to 0.0787 in.)

Coat the 3rd gear cone with gear oil.

Check the braking effect of the No. 2 synchronizer ring.

Using a feeler gauge, measure the clearance between the No. 2 synchronizer ring back and 3rd gear spline end.

• Standard clearance:
• 1.0 to 2.0 mm (0.0394 to 0.0787 in.)

Using a vernier caliper, measure the clearance between the reverse gear and No. 1 gear shift fork.

• Standard clearance:
• 0.15 to 0.35 mm (0.00591 to 0.0137 in.)

• Maximum clearance:
• 0.35 mm (0.0137 in.)

Check that the No. 1 transmission clutch hub and reverse gear slide smoothly.

Check that the splines of the reverse gear are not worn down.

Using a vernier caliper, measure the No. 2 hub sleeve and No. 2 gear shift fork as shown in the illustration.

• Standard clearance:
• 0.15 to 0.35 mm (0.00591 to 0.0137 in.)

Check the sliding condition between the No. 2 hub sleeve and No. 2 clutch hub.

Check that the splines of the No. 2 transmission hub sleeve are not worn down.

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

• Standard inside diameter:
• 44.015 to 44.040 mm (1.7329 to 1.7338 in.)

• Maximum inside diameter:
• 44.040 mm (1.7338 in.)

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

• Standard inside diameter:
• 44.015 to 44.040 mm (1.7329 to 1.7338 in.)

• Maximum inside diameter:
• 44.040 mm (1.7338 in.)

Using a cylinder gauge, measure the inside diameter of the 3rd gear.

• Standard inside diameter:
• 44.015 to 44.040 mm (1.7329 to 1.7338 in.)

• Maximum inside diameter:
• 44.040 mm (1.7338 in.)

Using a dial indicator, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.30 mm (0.00394 to 0.0118 in.)

Using a dial indicator, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Using a dial indicator, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Using a feeler gauge, measure the thrust clearance.

• Standard clearance:
• 0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Using a dial indicator, measure the radial clearance.

• Standard clearance:
• 0.009 to 0.056 mm (0.000355 to 0.00220 in.)

Using a dial indicator, measure the radial clearance.

• Standard clearance:
• 0.008 to 0.034 mm (0.000315 to 0.00133 in.)

Using a dial indicator, measure the radial clearance.

• Standard clearance:
• 0.008 to 0.034 mm (0.000315 to 0.00133 in.)

Using 2 screwdrivers and a hammer, tap off the snap ring from the output shaft.

Using SST and a press, remove the 5th gear, center bearing, 1st gear bearing inner race, 1st gear and 1st gear needle roller bearing from the output shaft.

• SST
• 09527-10011

Remove the No. 1 synchronizer ring from the No. 1 clutch hub.

Using a magnet hand, remove the lock ball.

Using SST and a press, remove the reverse gear, No. 1 transmission clutch hub, No. 1 synchronizer ring and 2nd gear.

• SST
• 09950-00020

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

Remove the needle roller bearing from the output shaft.

Remove the 2 synchromesh shifting key springs.

Remove the reverse gear and 3 synchromesh shifting keys from the transmission clutch hub.

Using a snap ring expander, remove the snap ring from the output shaft.

Using a press, remove the No. 2 transmission clutch hub and 3rd gear.

Remove the No. 1 synchronizer ring from the 3rd gear.

Remove the needle roller bearing from the output shaft.

Remove the 2 synchromesh shifting key springs.

Remove the transmission hub sleeve and 3 synchromesh shifting keys from the transmission clutch hub.

Using SST and a press, install a new front bearing.

• SST
• 09950-60010(09951-00400)
  09950-70010(09951-07100)

Select a snap ring that will allow minimal axial play.

• Standard clearance:
• 0.10 mm (0.0039 in.) or less

• Standard Front Bearing Shaft Snap Ring:

• Mark	Thickness
  0	2.05 to 2.10 mm (0.0807 to 0.0827 in.)
  1	2.10 to 2.15 mm (0.0827 to 0.0847 in.)
  2	2.15 to 2.20 mm (0.0847 to 0.0866 in.)
  3	2.20 to 2.25 mm (0.0866 to 0.0886 in.)
  4	2.25 to 2.30 mm (0.0886 to 0.0906 in.)
  5	2.30 to 2.35 mm (0.0906 to 0.0925 in.)

Using a snap ring expander, install the snap ring.

Coat the 13 input shaft bearings with MP grease and install them to the input shaft.

Coat the No. 2 synchronizer ring with gear oil and install it to the input shaft.

Coat the input shaft cone with gear oil.

Check the braking effect of the No. 2 synchronizer ring.

Using a feeler gauge, measure the clearance between the No. 2 synchronizer ring back and input shaft spline end.

• Standard clearance:
• 1.00 to 2.00 mm (0.0394 to 0.0787 in.)