Third, Fourth, Fifth and Sixth Gears Assembly Overview

Third, Fourth, Fifth and Sixth Gears Assembly Overview

=> [ Transmission, Assembly Sequence ] Transmission, Assembly Sequence

• After installing, 3rd through 6th selector gears must have 0.20 to 0.50 mm axial play.





1 Bearing housing

2 Oil collector tray

• With magnet

• Clipped into the reverse shaft support

3 Securing ring

• Install the thickest circlip that can just still be installed

• Determine thickness, refer to => [ Transmission, Assembly Sequence ] Transmission, Assembly Sequence

4 6th gear wheel

• Installation position: the higher inner collar faces the spacer sleeve => [ (Item 5) Spacer sleeve ]

5 Spacer sleeve

6 5th gear wheel

• Installation position: High inner collar faces 4th gear drive gear

7 4th gear wheel

• Installation position: High inner collar faces 5th gear drive gear

8 3rd gear wheel

• For moving and installing, the bearing housing must be removed from the transmission housing and the pinion must be removed. Refer to => [ Transmission, Assembly Sequence ] Transmission, Assembly Sequence.

9 Thrust washer

• For 3rd gear selector gear

10 Needle bearing

• For 3rd gear

11 3rd gear wheel

• Insert spring before installing, refer to => [ Inserting Spring into Selector Gear ] Input Shaft

• Check the axial play with a Feeler Gauge (0.20 to 0.50 mm) after installing

12 Synchronizer ring for 3rd gear

• Checking for wear, refer to => [ Checking Synchronizer Ring for Wear ] Input Shaft

13 Securing ring

• Identify

• Do not interchange with the circlip => [ (Item 15) Securing ring ]

14 Synchronizer hub for 3rd and 4th gears

• Installation position: high inner collar faces 3rd gear wheel

15 Securing ring

• Do not interchange with the circlip => [ (Item 13) Securing ring ]

• Determine thickness, refer to => [ Transmission, Assembly Sequence ] Transmission, Assembly Sequence

16 Locking collar for 3rd and 4th gear

• Mark the installation position of the synchronizer hub before removing

17 Dowel pin with clamp

• For attaching the 3rd and 4th gear shift fork and to the selector rod

18 Selector fork for 3rd and 4th gear

19 4th gear synchronizer ring

• Checking for wear, refer to => [ Checking Synchronizer Ring for Wear ] Input Shaft

20 4th gear wheel

• Insert spring before installing, refer to => [ Inserting Spring into Selector Gear ] Input Shaft

• Check the axial play with a Feeler Gauge (0.20 to 0.50 mm) after installing

21 Needle bearing

• For 4th gear

22 Thrust washer

• For 4th and 5th gear wheels

23 Inner race/needle bearing

• For 5th gear

24 Needle bearing

• For 5th gear

25 5th gear wheel

• Insert spring before installing, refer to => [ Inserting Spring into Selector Gear ] Input Shaft

• Check the axial play with a Feeler Gauge (0.20 to 0.50 mm) after installing

26 Synchronizer ring for 5th gear

• Checking for wear, refer to => [ Checking Synchronizer Ring for Wear ] Input Shaft

27 Synchronizer hub for 5th and 6th gears

28 Locking collar for 5th and 6th gear

• Mark the installation position of the synchronizer hub before removing

29 Inner race/needle bearing

• For 2nd gear

30 Needle bearing

• For 6th gear

31 6th gear synchronizer ring

• Checking for wear, refer to => [ Checking Synchronizer Ring for Wear ] Input Shaft

32 6th gear wheel

• Insert spring before installing, refer to => [ Inserting Spring into Selector Gear ] Input Shaft

• Check the axial play with a Feeler Gauge (0.20 to 0.50 mm) after installing

33 Thrust washer

• For 6th selector gear

34 Inner race

• For roller sleeve

35 Internal multi-point bolt, 150 Nm

36 Dowel pin with clamp

• For attaching the 5th and 6th gear shift fork and to the selector rod

37 Selector fork for 5th and 6th gear