Assembly

COUNTER SHAFT AND GEAR


Assembly






1. Install 3rd gear bushing to counter shaft with a pressing machine using the inserter [SST: ST30911000 ( - )].

CAUTION:
Be careful with the orientation of 3rd gear bushing.






2. Apply gear oil to 3rd needle bearing, 3rd inner baulk ring, 3rd synchronizer cone, and 3rd outer baulk ring.

CAUTION:
Replace 3rd inner baulk ring, 3rd synchronizer cone, and
3rd outer baulk ring as a set.
3. Install 3rd needle bearing, 3rd counter gear, 3rd inner baulk ring, 3rd synchronizer cone, and 3rd outer baulk ring to counter shaft.

NOTE:
4th outer baulk ring has three spaces that one gear tooth is missing but 3rd outer baulk ring doesn't.






4. Install 3rd-4th synchronizer hub assembly with the following procedure.
a. Install 3rd-4th coupling sleeve and 3rd-4th shifting inserts to 3rd-4th synchronizer hub.

CAUTION:
- Be careful with the shape of 3rd-4th shifting insert.





- Never reuse 3rd-4th coupling sleeve and 3rd-4th synchronizer hub.
- Replace 3rd-4th coupling sleeve and 3rd-4th synchronizer hub as a set.
b. Install 3rd-4th spread springs to 3rd-4th shifting inserts.

CAUTION:
Never install 3rd-4th spread spring hook onto the same 3rd-4th shifting insert.





c. Apply gear oil to the hole spline press fitting side of 3rd-4th synchronizer hub.
d. Install 3rd-4th synchronizer hub assembly (1) to counter shaft with a pressing machine using the inserter (A) [SST:





ST30911000 ( - )].

CAUTION:
Be careful with the orientation of 3rd-4th coupling sleeve.






5. Install 4th counter gear thrust washer with the following procedure.





a. Set 4th counter gear thrust washer (1), 4th gear bushing, 4th needle bearing, and 4th counter gear to the inserter (A) [SST:
KV40100630 (J-26092)].

CAUTION:
Be careful with the orientation of 4th counter gear thrust washer.






b. Apply gear oil to 4th needle bearing, 4th outer baulk ring, 4th synchronizer cone, and 4th inner baulk ring.

CAUTION:
Replace 4th outer baulk ring, 4th synchronizer cone, and
4th inner baulk ring as a set.
c. Install 4th outer baulk ring, 4th synchronizer cone, and 4th inner baulk ring to 4th counter gear.

NOTE:
4th outer baulk ring has three spaces that one gear tooth is missing but 3rd outer baulk ring doesn't.






d. Install 4th gear bushing, 4th needle bearing, and 4th counter gear together with 4th counter gear thrust washer to counter shaft with a pressing machine.





6. Install counter rear bearing inner race (1) to counter shaft with a pressing machine using the inserter (A) [SST: ST30032000 (J-26010-01)].

CAUTION:
- Replace counter rear bearing inner race, counter rear bearing, and counter rear bearing spacer as a set.





- Be careful with the orientation of counter rear bearing inner race.