1. Inspect 4th gear thrust clearance
4Th gear thrust clearance:
2. Inspect 3rd gear thrust clearance
3Rd gear thrust clearance:
3. Inspect 4th gear radial clearance
4Th gear radial clearance:
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
4. Inspect 3rd gear radial clearance
3Rd gear radial clearance:
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
5. Remove 4th gear
Hint
: using a waste to prevent the snap ring from being scattered.
Sst 09950–00020
Notice
:
6. Remove 4th gear needle roller bearing
7. Remove 4th gear synchronizer ring
8. Remove 3rd gear
Hint
: using a waste to prevent the snap ring from being scattered.
Sst 09950–00020
Notice
:
9. Remove 3rd gear synchronizer ring
10. Remove 3rd gear needle roller bearing
11. Remove transmission hub sleeve no.2
Hint
: using a waste to prevent the shifting key and shifting key spring from being scattered.
12. Inspect input shaft
Maximum runout: 0.015 Mm(0.0006 In.) If the runout exceeds the maximum, replace the input shaft.
Input shaft outer diameter:
If the outer diameter is below the minimum, replace the input shaft.
13. Inspect 4th gear
Standard inside diameter: 34.015 – 34.031 Mm (1.3391 – 1.3398 In.) Maximum inside diameter: 34.031 Mm (1.3398 In.)
If the inside diameter exceeds the maximum, replace the 4th gear.
14. Inspect 3rd gear
Standard inside diameter: 36.015 – 36.031 Mm (1.4179 – 1.4185 In.) Maximum inside diameter: 36.031 Mm (1.4185 In.)
If the inside diameter exceeds the maximum, replace the 3rd gear.
15. Inspect 3rd gear synchronizer ring
Turn the 3rd gear synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the fine lapping compound between 3rd gear synchronizer ring and 3rd gear cone. Lightly rub the 3rd gear synchronizer ring and 3rd gear cone together.
Notice
: ensure the fine lapping compound is completely washed off after rubbing.
Minimum clearance:
0.65 Mm (0.0256 In.)
If the clearance below than the minimum, replace the 3rd gear synchronizer ring, and apply small amount of the fine lapping compound on gear cone.
Notice
: ensure the fine lapping compound is completely washed off after rubbing.
16. Inspect 4th gear synchronizer ring
Turn the 4th gear synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the fine lapping compound between 4th gear synchronizer ring and 4th gear cone. Lightly rub the 4th gear synchronizer ring and 4th gear cone.
Notice
: ensure the fine lapping compound is completely washed off after rubbing.
Minimum clearance: 0.75 Mm (0.0295 In.) If the clearance below than the minimum, replace the 4th gear synchronizer ring, and apply small amount of the fine lapping compound on gear cone.
Notice
: ensure the fine lapping compound is completely washed off after rubbing.
17. Inspect transmission hub sleeve no.2
Standard clearance:
0.15 – 0.35 Mm (0.0059 – 0.0137 In.)
If the clearance is out of specification, replace the transmission hub sleeve no.2 And gear shift fork no.2.
18. Install transmission hub sleeve no.2
Notice
: do not set the transmission clutch hub sleeve no.2 And the transmission clutch hub no.2 In incorrect orientation.
Hint
: do not set the both openings of the shifting key springs in the same position.
19. Install 3rd gear needle roller bearing
20. Install 3rd gear
21. Install 3rd gear synchronizer ring
22. Install transmission clutch hub no.2
Sst 09316–60011 (09316–00021)
Snap ring thickness:
Notice
: take care not to damage the journal surface of the input shaft.
23. Install 4th gear synchronizer ring
24. Install 4th gear needle roller bearing
25. Install 4th gear
26. Install input shaft rear radial ball bearing
Sst 09636–20010
Snap ring thickness:
Notice
: take care not to damage the journal surface of the snap ring.
27. Inspect 3rd gear radial clearance
3Rd gear radial clearance:
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
28. Inspect 4th gear radial clearance
4Th gear radial clearance:
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
29. Inspect 3rd gear thrust clearance
29. Inspect 3rd gear thrust clearance
3Rd gear thrust clearance:
30. Inspect 4th gear thrust clearance
4Th gear thrust clearance:
Glossary of tire terminology
*: Table 1 - Occupant loading and distribution for vehicle normal load for various
designated seating capacities
...
Timing gear cover oil seal
Replacement
1. Remove engine under cover rh
2. Remove front wheel rh
3. Remove fan and generator v belt
Turn the v–ribbed belt tensioner slowly clockwise and
loosen it. Then, remove the fan and generator belt v and
put back the v–ribbed belt tensioner little by little and fix
it qui ...
Replacement
1. Remove hood sub–assy
2. Remove cylinder head cover no.2
3. Remove battery
4. Remove battery carrier
Remove the 4 bolts and battery carrier.
5. Remove air cleaner assembly with hose
6. Remove floor shift cable transmission control shift
Remove the nut from the control shaft ...