3rd to 6th Gear, Removing and Installing

3rd to 6th gear, removing and installing - 6 Spd. Manual Transmission 02X All Wheel Drive

Note:
^ 3rd to 6th speed selector gears should have an axial play of 0.20 to 0.50 mm after installing.





1 - Bearing housing
2 - Oil collector

^ With magnet
^ Clipped into reverse shaft support.

3 - Circlip

^ Install thickest circlip that will still just fit.
^ Re-determining thickness

4 - 6th gear wheel
5 - Spacer sleeve
6 - 5th gear wheel

^ Installation position: high inside collar faces 4th gear wheel

7 - 4th gear wheel

^ Installation position: high inside collar faces 5th gear wheel

8 - 3rd gear wheel

^ Detach bearing housing from transmission housing and remove pinion shaft prior to removing and installing Disassembling and assembling sequence

9 - Thrust washer

^ For 3rd speed selector gear

10 - Needle bearing

^ For 3rd gear

11 - 3rd speed selector gear

^ Insert spring before installing
^ Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

12 - 3rd gear synchro-ring

^ Checking for wear

13 - Circlip

^ Mark

14 - Synchronizing hub for 3rd and 4th gear


^ Installation position: high inside collar faces 3rd speed selector gear

15 - Circlip

^ Re-determining thickness

16 - Locking collar for 3rd and 4th gear

^ Mark position in relation to synchronizing hub prior to removing

17 - Pin with clip

^ For securing selector fork for 3rd and 4th gear to selector rod

18 - Selector fork for 3rd and 4th gear
19 - 4th gear synchro-ring

^ Checking for wear

20 - 4th speed selector gear

^ Insert spring before installing
^ Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

21 - Needle bearing

^ For 4th gear

22 - Thrust washer

^ For 4th speed and 5th speed selector gears

23 - Needle bearing inner race

^ For 5th gear

24 - Needle bearing

^ For 5th gear

25 - 5th speed selector gear

^ Insert spring before installing
^ Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

26 - 5th gear synchro-ring

^ Checking for wear

27 - Synchronizing hub for 5th and 6th gear
28 - Locking collar for 5th and 6th gear

^ Mark position in relation to synchronizing hub prior to removing

29 - Needle bearing inner race

^ For 6th gear

30 - Needle bearing

^ For 6th gear

31 - 6th gear synchro-ring

^ Checking for wear

32 - 6th speed selector gear

^ Insert spring before installing
^ Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

33 - Thrust washer

^ For 6th speed selector gear

34 - Inner race

^ For needle roller bearing

35 - Multi-point socket head bolt, 150 Nm
36 - Pin with clip

^ For securing selector fork for 5th and 6th gear to selector rod

37 - Selector fork for 5th and 6th gear