Assembly

COUNTER SHAFT AND GEAR


Assembly






1. Using the inserter [SST: ST30911000 ( - )] and a press to press fit 3rd gear bushing onto counter shaft.

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





2. Install 3rd-4th coupling sleeve and 3rd-4th shifting inserts into 3rd-4th synchronizer hub.

CAUTION:
- Be careful with the shape of reverse shifting insert to avoid mis-assembly.





- Never reuse 3rd-4th coupling sleeve and 3rd-4th synchronizer hub.
- Replace 3rd-4th coupling sleeve and 3rd-4th synchronizer hub as a set.
3. 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.





4. Apply gear oil to 3rd needle bearing, 3rd inner baulk ring, 3rd synchronizer cone and 3rd outer baulk ring.
5. Apply gear oil to the hole spline press fitting side of 3rd-4th synchronizer hub.





6. Install 3rd needle bearing, 3rd counter gear (1), 3rd inner baulk ring, 3rd synchronizer cone and 3rd outer baulk ring on counter shaft and then using the inserter (A) [SST: ST30911000 ( - )] and a press to press-fit 3rd-4th synchronizer hub assembly (2).

CAUTION:
- Replace 3rd inner baulk ring, 3rd synchronizer cone and
3rd outer baulk ring as a set.





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

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





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





8. Install 4th outer baulk ring, 4th synchronizer cone, 4th inner baulk ring, 4th needle bearing and 4th counter gear (1) onto counter shaft and then using the inserter (A) [SST: KV40100630
(J-26092)] and a press to press-fit 4th gear bushing and 4th counter gear thrust washer (2).

CAUTION:
- Replace 4th outer baulk ring, 4th synchronizer cone and
4th inner baulk ring as a set.





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





9. Using the inserter (A) [SST: ST30032000 (J-26010-01)] and a press to press-fit counter rear bearing inner race (1) onto counter shaft.

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.