Assembly

MAINSHAFT AND GEAR


Assembly

1. Install 5th-6th coupling sleeve and 5th-6th shifting inserts to 5th-6th synchronizer hub.

CAUTION:
- Be careful with the orientation of 5th-6th coupling sleeve.





6th main gear side

- Never reuse 5th-6th coupling sleeve and 5th-6th synchronizer hub.
- Replace 5th-6th coupling sleeve and 5th-6th synchronizer hub as a set.





- Be careful with the orientation of 5th-6th synchronizer hub.





- Be careful with the shape of reverse shifting insert to avoid mis-assembly.
2. Install 5th-6th spread springs to 5th-6th shifting inserts.

CAUTION:
Never install 5th-6th spread spring hook onto the same 5th-6th shifting insert.





3. Apply gear oil to 6th needle bearing and 6th baulk ring.
4. Install 6th needle bearing, 6th main gear, and 6th baulk ring on mainshaft and then using the inserter [SST: ST30911000 ( - )]





and a press to press-fit 5th-6th synchronizer hub assembly.

CAUTION:
Be careful with the orientation of 5th-6th coupling sleeve.





NOTE:
5th and 6th baulk rings have three spaces that four gear teeth are missing as shown in the figure.





5. Select and install a snap ring so that the end play comes within the standard value.

End play standard value : Refer to End Play End Play





CAUTION:
Never reuse snap ring.
6. Install 1st-2nd coupling sleeve and 1st-2nd shifting inserts to 1st-2nd synchronizer hub.

CAUTION:
- Be careful with the orientation of 1st-2nd coupling sleeve.





- Never reuse 1st-2nd coupling sleeve and 1st-2nd synchronizer hub.
- Replace 1st-2nd coupling sleeve and 1st-2nd synchronizer hub as a set.





- Be careful with the orientation of 1st-2nd synchronizer hub.





- Be careful with the shape of reverse shifting insert to avoid mis-assembly.
7. Install 1st-2nd spread springs to 1st-2nd shifting inserts.

CAUTION:
Never install 1st-2nd spread spring hook onto the same 1st-2nd shifting insert.





8. Apply gear oil to 2nd needle bearing, 2nd inner baulk ring, 2nd synchronizer cone, and 2nd outer baulk ring.
9. Install 2nd main gear, 2nd needle bearing, 2nd inner baulk ring, 2nd synchronizer cone, and 2nd outer baulk ring on mainshaft and then using the support ring [SST: ST27861000 ( - )] and a press to press-fit 1st-2nd synchronizer hub assembly.






CAUTION:
- Replace 2nd inner baulk ring, 2nd synchronizer cone and
2nd outer baulk ring as a set.





- Be careful with the orientation of 1st-2nd coupling sleeve.

NOTE:
1st outer baulk ring has three spaces that four gear tooth is missing and 2nd outer baulk ring has three spaces that two gear teeth are missing.





10. Using the support ring [SST: ST27861000 ( - )] and a press to press-fit 1st gear bushing.





11. Apply gear oil to 1st needle bearing, 1st outer baulk ring, 1st synchronizer cone and 1st inner baulk ring.
12. Install 1st outer baulk ring, 1st synchronizer cone, 1st inner baulk ring, 1st needle bearing and 1st main gear (1) on mainshaft and then using the inserter (A) [SST: ST30022000 ( - )] and a press to press-fit 3rd main gear (2).






CAUTION:
- Replace 1st outer baulk ring, 1st synchronizer cone and
1st inner baulk ring as a set.





- Be careful with the orientation of 3rd main gear.





NOTE:
1st outer baulk ring has three spaces that four gear tooth is missing and 2nd outer baulk ring has three spaces that two gear teeth are missing.





13. Install 3rd-4th main spacer (1) on mainshaft and then using the inserter (A) [SST: ST30022000 ( - )] and a press to press-fit 4th main gear (2).





CAUTION:
Be careful with the orientation of 4th main gear.





14. Using the inserter [SST] and a press to press-fit mainshaft bearing onto mainshaft.





15. Using the inserter [SST: ST30911000 ( - )] and a press to press fit reverse main gear bushing onto mainshaft.