Disassembly

RA61F MANUAL TRANSMISSION: INPUT SHAFT: DISASSEMBLY

1. INSPECT 6TH GEAR THRUST CLEARANCE





(a) Using a dial indicator, measure the 6th gear thrust clearance.

Standard clearance:

0.20 to 0.49 mm (0.0079 to 0.0193 in.)

If the clearance is outside the specification, replace the defective gear, spacer or shaft.

2. INSPECT 3RD GEAR THRUST CLEARANCE





(a) Using a feeler gauge, measure the 3rd gear thrust clearance.

Standard clearance:

0.09 to 0.52 mm (0.0035 to 0.0205 in.)

If the clearance is outside the specification, replace the defective gear, thrust washer, clutch hub or shaft.

3. INSPECT 4TH GEAR THRUST CLEARANCE





(a) Using a dial indicator, measure the 4th gear thrust clearance.

Standard clearance:

0.12 to 0.38 mm (0.0047 to 0.0150 in.)

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

4. INSPECT 6TH GEAR RADIAL CLEARANCE





(a) Using a dial indicator, measure the 6th 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 defective gear, needle roller bearing or shaft.

5. INSPECT 3RD GEAR RADIAL CLEARANCE





(a) Using a dial indicator, measure the 3rd 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 defective gear, needle roller bearing or shaft.

6. INSPECT 4TH GEAR RADIAL CLEARANCE





(a) Using a dial indicator, measure the 4th 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 defective gear, needle roller bearing or shaft.

7. REMOVE TRANSMISSION CLUTCH HUB NO.3 SHAFT SNAP RING





(a) Using 2 screwdrivers and a hammer, tap out the snap ring.

HINT
Use a piece of cloth to prevent the snap ring from flying off.

8. REMOVE 6TH GEAR





(a) Using SST and a press, remove transmission clutch hub No. 3, the hub sleeve, synchronizer ring and 6th gear from the input shaft.

SST : 09950-00020

SST : 09950-70010

09951-07200

SST : 09950-60010

09951-00300

NOTICE:
* Do not tighten SST excessively.
* Support the input shaft by hand so that it does not fall off.

9. REMOVE 6TH GEAR NEEDLE ROLLER BEARING





(a) Remove the 6th gear needle roller bearing from the input shaft.

10. REMOVE SPACER





(a) Remove the spacer from the input shaft.

11. REMOVE GEAR THRUST WASHER SHAFT SNAP RING





(a) Using a snap ring expander, remove the snap ring from the input shaft.

12. REMOVE 3RD GEAR THRUST WASHER





(a) Remove the 3rd gear thrust washer from the input shaft.

13. REMOVE 3RD GEAR





(a) Remove the 3rd gear from the input shaft.

14. REMOVE STRAIGHT PIN





(a) Remove the straight pin from the input shaft.

15. REMOVE 3RD GEAR NEEDLE ROLLER BEARING





(a) Remove the 3rd gear needle roller bearing from the input shaft.

16. REMOVE SPACER





(a) Remove the spacer from the input shaft.

17. REMOVE NO. 2 SYNCHRONIZER RING SET





(a) Remove the No. 2 synchronizer ring set from the input shaft.

18. REMOVE CLUTCH HUB NO.2 SETTING SHAFT SNAP RING





(a) Using a snap ring expander, remove the snap ring from the input shaft.

19. REMOVE 4TH GEAR





(a) Using SST and a press, remove transmission clutch hub No. 2, the hub sleeve, synchronizer ring and 4th gear from the input shaft.

SST : 09950-00020

NOTICE:
Support the input shaft by hand so that it does not fall off.

20. REMOVE 4TH GEAR NEEDLE ROLLER BEARING





(a) Remove the 4th gear needle roller bearing from the input shaft.

21. REMOVE INPUT SHAFT FRONT BEARING SNAP RING





(a) Using 2 screwdrivers and a hammer, tap out the snap ring.

HINT
Use a piece of cloth to prevent the snap ring from flying off.

22. REMOVE INPUT SHAFT FRONT BEARING





(a) Using SST and a press, remove the input shaft front bearing from the input shaft.

SST : 09950-00020

NOTICE:
Support the input shaft by hand so that it does not fall off.

23. REMOVE NO. 2 TRANSMISSION CLUTCH HUB





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

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

24. REMOVE NO. 3 TRANSMISSION CLUTCH HUB

(a) Perform the same procedures as for the No. 2 clutch hub.