DISASSEMBLY

Removal / installation

1. INSPECT REVERSE GEAR THRUST CLEARANCE

1. Using a feeler gauge, measure the reverse gear thrust clearance.
   

   Standard clearance:

   0.12 to 0.28 mm (0.0047 to 0.0110 in.)
   

   If the clearance is outside the specification, replace the defective gear, spline piece or bearing race.
   

2. INSPECT 1ST GEAR THRUST CLEARANCE

1. Using a dial indicator, measure the 1st gear thrust clearance.
   

   Standard clearance:

   0.10 to 0.42 mm (0.0039 to 0.0165 in.)
   

   If the clearance is outside the specification, replace the defective gear, clutch hub, spline piece or counter gear.
   

3. INSPECT 2ND GEAR THRUST CLEARANCE

1. Using a dial indicator, measure the 2nd gear thrust clearance.
   

   Standard clearance:

   0.10 to 0.42 mm (0.0039 to 0.0165 in)
   

   If the clearance is outside the specification, replace the defective gear, clutch hub or counter gear.
   

4. INSPECT REVERSE GEAR RADIAL CLEARANCE

1. Using a dial indicator, measure the reverse gear radial clearance.
   

   Standard clearance:

   0.015 to 0.065 mm (0.0006 to 0.0026 in.)
   

   If the clearance is outside the specification, replace the reverse gear, reverse gear needle roller bearing or bearing race.
   

5. INSPECT 1ST GEAR RADIAL CLEARANCE

1. Using a dial indicator, measure the 1st gear radial clearance.
   

   Standard clearance:

   0.015 to 0.067 mm (0.0006 to 0.0026 in.)
   

   If the clearance is outside the specification, replace the 1st gear, needle roller bearing or shaft.
   

6. INSPECT 2ND GEAR RADIAL CLEARANCE

1. Using a dial indicator, measure the 2nd radial clearance.
   

   Standard clearance:

   0.015 to 0.067 mm (0.0006 to 0.0026 in.)
   

   If the clearance is outside the specification, replace the 2nd gear, needle roller bearing or shaft.
   

7. REMOVE NO. 1 COUNTER GEAR FRONT BEARING SNAP RING

1. Using a snap ring expander, remove the snap ring from the counter gear.
   

8. REMOVE COUNTER GEAR FRONT BEARING

1. Using SST and a press, remove the counter gear front bearing from the counter gear.
   

   SST

   09950-00020  
   09950-70010   (09951-07100)
   09950-60010   (09951-00320)
   

9. REMOVE REVERSE GEAR BEARING RACE INNER

1. Remove the reverse gear bearing race inner from the counter gear.
   

10. REMOVE COUNTER SHAFT REVERSE GEAR

1. Remove the counter shaft reverse gear with the hub sleeve, 2 shifting keys and key spring from the counter gear.
   

11. REMOVE REVERSE GEAR NEEDLE ROLLER BEARING

1. Remove the reverse gear needle roller bearing from the counter gear.
   

12. REMOVE NO. 4 SYNCHRONIZER RING

1. Remove the No. 4 synchronizer ring from the counter gear.
   

13. REMOVE DETENT BALL

1. Remove the ball from the counter gear.
   

14. REMOVE COUNTER SHAFT GEAR 1ST SPEED

1. Using a press, remove the counter shaft gear 1st speed together with reverse gear spline piece from the counter gear.
   

   SST

   09950-00020  
   

15. REMOVE 1ST GEAR NEEDLE ROLLER BEARING

1. Remove the 1st gear needle roller bearing from the counter gear.
   

16. REMOVE NO. 1 SYNCHRONIZER RING SET (for 1st Gear)

1. Remove the No. 1 synchronizer ring set from the counter gear.
   

17. REMOVE CLUTCH HUB NO. 1 SHAFT SNAP RING

1. Using a snap ring expander, remove the snap ring from the counter gear.
   

18. REMOVE COUNTER SHAFT 2ND SPEED GEAR

1. Using a press, remove the counter shaft 2nd speed gear together with the No. 1 transmission clutch hub from the counter gear.
   

   SST

   09950-00020  
   

19. REMOVE 2ND GEAR NEEDLE ROLLER BEARING

1. Remove the 2nd needle roller bearing from the counter gear.
   

20. REMOVE NO. 1 SYNCHRONIZER RING SET (for 2nd Gear)

1. Remove the No. 1 synchronizer ring set from the 2nd gear.
   

21. REMOVE NO. 1 TRANSMISSION CLUTCH HUB

1. Remove the hub sleeve, 3 synchromesh shifting keys, 3 balls and 3 springs from the clutch hub.
   

   HINT:

   Use a shop rag or a piece of cloth to prevent the ball and spring from flying off.

22. REMOVE SNAP RING COUNTER GEAR REAR BEARING

1. Using a snap ring expander, remove the snap ring from the counter gear.
   

23. REMOVE RADIAL BALL BEARING INNER RACE

1. Using SST and a press, remove the needle roller bearing inner race.
   

   SST

   09950-00020