COUNTER GEAR DISASSEMBLY


  1. INSPECT COUNTER SHAFT 5TH GEAR RADIAL CLEARANCE


    1. A01KGCY

      Install the 5th gear bearing inner lace lock ball, 5th gear thrust washer and the counter shaft 5th gear assembly to the counter gear.

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

      Standard clearance
      0.008 to 0.034 mm (0.0003 to 0.00134 in.)

      If the clearance exceeds the maximum, replace the counter 5th gear bearing.

  2. REMOVE TRANSMISSION HUB SLEEVE NO.3


    1. A01KHF1

      Remove the transmission hub sleeve No. 3, 3 clutch hub No. 3 synchromesh shifting keys, 2 synchromesh shifting key springs No. 3 and the counter 5th gear bearing from the counter shaft 5th gear.

  3. INSPECT SYNCHRONIZER RING NO.3


    1. A01KGJ7

      Coat the gear spline piece No. 5 cone with gear oil. Check the braking effect of the synchronizer ring No. 3. Turn the synchronizer ring No. 3 in one direction while pushing it to the gear spline piece No. 5 cone. Check that the ring locks.

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

      Note

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

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

    3. A01KG9D

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

      Standard clearance
      0.85 to 1.55 mm (0.0335 to 0.0610 in.)

      If the clearance is less than the minimum, replace the synchronizer ring No. 3 and apply a small amount of the fine lapping compound on the gear spline piece No. 5 cone.

      Note

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

  4. INSPECT TRANSMISSION HUB SLEEVE NO.3


    1. A01KH6N

      Check the sliding condition between the transmission hub sleeve No. 3 and the transmission clutch hub No. 3.

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

    3. A01KFCL

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

      Standard clearance
      0.25 to 0.45 mm (0.0098 to 0.0177 in.)

      If the clearance exceeds the standard clearance, replace the transmission hub sleeve No. 3 and the gear shift fork No. 3.

  5. INSPECT COUNTER SHAFT 5TH GEAR


    1. A01KH02

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

      Standard clearance
      33.015 to 33.040 mm (1.2998 to 1.3008 in.)
      Maximum clearance
      33.040 mm (1.3008 in.)

      If the clearance exceeds the maximum, replace the counter shaft 5th gear.

  6. INSPECT COUNTER GEAR


    1. A01KG8W

      Using a micrometer, measure the outer diameter of the counter gear journal surface.

      Standard clearance
      25.984 to 26.000 mm (1.0230 to 1.0236 in.)
      Minimum clearance
      25.984 mm (1.0230 in.)

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

  7. INSPECT COUNTER GEAR FRONT BEARING OR ROLLER


    1. A01KI3T

      Make sure the counter gear front bearing or roller rotates smoothly.

  8. REMOVE COUNTER GEAR FRONT BEARING OR ROLLER


    1. A01KGXGE01

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

    2. A01KHMGE01

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

      SST
      09950-00020