ЗАДАЮЩАЯ ШЕСТЕРНЯ ПОВТОРНАЯ СБОРКА


  1. INSTALL COUNTER GEAR REAR RADIAL BALL BEARING

    A01DNUUE01

    1. 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 )

  2. INSTALL COUNTER GEAR REAR BEARING SNAP RING

    A01DQVLE01

    1. 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.)

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

  3. INSTALL NO. 1 TRANSMISSION CLUTCH HUB

    A01DSKPE02
    Text in Illustration
    *a 1st Gear Side
    *b 2nd Gear Side

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

    2. Install the clutch hub to the clutch hub sleeve.

    3. Install one of the balls to each shifting key.

    4. Install one of the springs to each shifting key.

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

      Note

      Be careful to prevent the balls from flying off.

  4. INSTALL 2ND GEAR NEEDLE ROLLER BEARING

    A01DUM7E01

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

  5. INSTALL COUNTER SHAFT 2ND SPEED GEAR

    A01DT6NE01
    Text in Illustration
    *a Groove
    *b Protrusion

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

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

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

      SST
      09316-60011

      Tech Tips

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

    4. Check that the gear and synchronizer ring move smoothly.

  6. INSTALL NO. 1 CLUTCH HUB SHAFT SNAP RING

    A01DRWOE01

    1. 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.)

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

  7. INSTALL NO. 1 SYNCHRONIZER RING SET (for 1st Gear)

    A01DQVJE01

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

  8. INSTALL 1ST GEAR NEEDLE ROLLER BEARING

    A01DQ4KE01

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

  9. INSTALL COUNTER SHAFT 1ST SPEED GEAR

    A01DM29E01

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

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

      SST
      09309-37010

  10. INSTALL BALL

    A01DSXXE01

    1. Install the ball to the counter gear.

  11. INSTALL NO. 4 SYNCHRONIZER RING

    A01DUOSE01

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

  12. INSTALL REVERSE GEAR NEEDLE ROLLER BEARING

    A01DUMTE01

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

  13. INSTALL COUNTERSHAFT REVERSE GEAR

    A01DNWPE03
    Text in Illustration
    *1 Reverse Gear
    *2 Hub Sleeve
    *3 Shifting Key
    *4 Key Spring

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

      Tech Tips


      • Install each shifting key with its groove on the reverse gear side.

      • Install the key spring with its claw on the reverse gear side.

      • Refer to the illustration when installing the key spring.

    2. Install the hub sleeve to the reverse gear.

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

  14. INSTALL REVERSE GEAR BEARING RACE INNER

    A01DNCCE01

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

  15. INSTALL COUNTER GEAR FRONT BEARING

    A01DSF6E04
    Text in Illustration
    *a Groove

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

      SST
      09608-06041

      Tech Tips

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

  16. INSTALL NO. 1 COUNTER GEAR FRONT BEARING SNAP RING

    A01DOMSE01

    1. 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.)

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

  17. INSPECT REVERSE GEAR THRUST CLEARANCE

    A01DUINE01

    1. 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.

      Tech Tips

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

  18. INSPECT 1ST GEAR THRUST CLEARANCE

    A01DTL8E01

    1. 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.

      Tech Tips

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

  19. INSPECT 2ND GEAR THRUST CLEARANCE

    A01DQB8E01

    1. 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.

      Tech Tips

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

  20. INSPECT REVERSE GEAR RADIAL CLEARANCE

    A01DQHXE01

    1. 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.

      Tech Tips

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

  21. INSPECT 1ST GEAR RADIAL CLEARANCE

    A01DMHXE01

    1. 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.

      Tech Tips

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

  22. INSPECT 2ND GEAR RADIAL CLEARANCE

    A01DTL7E01

    1. 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.