Disassembly

RA61F MANUAL TRANSMISSION: COUNTER GEAR: DISASSEMBLY

1. INSPECT REVERSE GEAR THRUST CLEARANCE





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

Standard clearance:

0.125 to 0.375 mm (0.0049 to 0.0148 in.)

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

2. INSPECT 1ST GEAR THRUST CLEARANCE





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

Standard clearance:

0.10 to 0.43 mm (0.0039 to 0.0169 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





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

Standard clearance:

0.10 to 0.43 mm (0.0039 to 0.0169 in.)

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

4. INSPECT REVERSE GEAR RADIAL CLEARANCE





(a) 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 needle roller bearing or shaft.

5. INSPECT 1ST GEAR RADIAL CLEARANCE





(a) 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





(a) Using a dial indicator, measure the 2nd 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 2nd gear needle roller bearing or shaft.

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





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

8. REMOVE COUNTER GEAR FRONT BEARING OR ROLLER





(a) Using SST and a press, remove the counter gear front bearing or roller from the counter gear.

SST : 09950-00020

SST : 09950-70010

09951-07100

SST : 09950-60010

09951-00320

9. REMOVE REVERSE GEAR BEARING RACE INNER





(a) Remove the reverse gear bearing race inner from the counter gear.

10. REMOVE COUNTERSHAFT REVERSE GEAR





(a) Remove the countershaft reverse gear from the counter gear.

(b) Remove the hub sleeve, 2 shifting keys and key spring from the countershaft reverse gear.

11. REMOVE REVERSE GEAR NEEDLE ROLLER BEARING





(a) Remove the reverse gear needle roller bearing from the counter gear.

12. REMOVE NO. 4 SYNCHRONIZER RING





(a) Remove the No. 4 synchronizer ring from the counter gear.

13. REMOVE BALL





(a) Remove the ball from the counter gear.

14. REMOVE COUNTERSHAFT GEAR 1ST SPEED





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

SST : 09950-00020

15. REMOVE 1ST GEAR NEEDLE ROLLER BEARING





(a) Remove the 1st gear needle roller bearing from the counter gear.

16. REMOVE NO. 1 SYNCHRONIZER RING SET (FOR 1ST GEAR)





(a) Remove the No. 1 synchronizer ring set from the counter gear.

17. REMOVE CLUTCH HUB NO.1 SHAFT SNAP RING





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

18. REMOVE COUNTER SHAFT 2ND SPEED GEAR





(a) 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





(a) Remove the 2nd needle roller bearing from the counter gear.

20. REMOVE NO. 1 SYNCHRONIZER RING SET (FOR 2ND GEAR)





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

21. REMOVE NO. 1 TRANSMISSION CLUTCH HUB





(a) Remove the hub sleeve, 3 synchromesh shifting keys, 3 balls and 3 springs from the clutch hub.

HINT
Use a piece of cloth to prevent the ball and spring from flying off.

22. REMOVE SNAP RING COUNTER GEAR REAR BEARING





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

23. REMOVE RADIAL BALL BEARING INNER RACE





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

SST : 09950-00020