Gear: Service and Repair

1. Remove the six 5th gear housing mounting bolts.




2. Remove the spring pin from the 5th gear shift fork.




3. Remove the outside parts from the mainshaft.
4. Reinstall the synchro hub and the ball bearing onto the mainshaft.




5. Clean all sealant residue from the transmission housing, then measure from the top of the ball bearing's outer race to the mounting flange for the 5th gear housing. Measure at two points and average the reading.




6. Remove the 52 mm snap ring and the oil guide plate from the 5th gear housing.




7. Place a straight edge on the 5th gear housing and measure the depth of the snap ring thrust shim installation hole. Measure at two points and average the readings. Subtract the thickness of the straight edge from the reading.




8. Select the correct thickness snap ring as follows:
(a) Subtract the bearing height (step 5) from the depth of the end cover (step 7).
(b) Subtract the Standard Clearance 0.11 mm - 0.18 mm (0.004 - 0.007 in.) from the dimension determined in step 8a,