Assembly
MAINSHAFT AND GEAR
Assembly
1. Apply gear oil to 6th needle bearing and 6th baulk ring.
2. Install 6th needle bearing, 6th main gear, and 6th baulk ring to mainshaft.
NOTE:
5th and 6th baulk rings have three spaces that four gear teeth are missing as shown in the figure.
3. Install 5th-6th synchronizer hub assembly with the following procedure.
a. 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.
Arrow :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.
A : 5th main gear side
B : 6th main gear side
- Be careful with the shape of 5th-6th shifting insert.
b. 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.
c. Install 5th-6th synchronizer hub assembly to mainshaft with a pressing machine using the inserter (A) [SST: ST30911000 ( - )].
CAUTION:
Be careful with the orientation of 5th-6th coupling sleeve.
Arrow :6th main gear side
4. Select and install snap ring (1) to mainshaft so that the end play "L" of mainshaft is adjusted to the standard value. For selecting snap ring, refer to the latest parts information.
2 : 5th-6th synchronizer hub
End play "L" : End Play "End Play".
5. Apply gear oil to 2nd needle bearing, 2nd inner baulk ring, 2nd synchronizer cone, and 2nd outer baulk ring.
CAUTION:
Replace 2nd inner baulk ring, 2nd synchronizer cone, and
2nd outer baulk ring as a set.
6. Install 2nd needle bearing, 2nd main gear, 2nd inner baulk ring, 2nd synchronizer cone, and 2nd outer baulk ring to mainshaft.
NOTE:
1st outer baulk ring has three spaces that four gear teeth are missing and 2nd outer baulk ring has three spaces that two gear teeth are missing.
A : 1st outer baulk ring
B : 2nd outer baulk ring
7. Install 1st-2nd synchronizer hub assembly with the following procedure.
a. 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.
Arrow: 2nd main gear side
- 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.
A : 2nd main gear side
B : 1st main gear side
- Be careful with the shape of 1st-2nd shifting insert.
b. 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.
c. Install 1st-2nd synchronizer hub assembly (1) to mainshaft with a pressing machine using the support ring (A) [SST:
ST27861000 ( - )].
2 : 2nd main gear
CAUTION:
Be careful with the orientation of 1st-2nd coupling sleeve.
Arrow :2nd main gear side
8. Install 1st gear bushing (1) to mainshaft with a pressing machine using the support ring (A) [SST: ST27861000 ( - )].
9. Apply gear oil to 1st needle bearing, 1st outer baulk ring, 1st synchronizer cone, and 1st inner baulk ring.
CAUTION:
Replace 1st outer baulk ring, 1st synchronizer cone, and
1st inner baulk ring as a set.
10. Install 1st outer baulk ring, 1st synchronizer cone, 1st inner baulk ring, 1st needle bearing, and 1st main gear to mainshaft.
NOTE:
1st outer baulk ring has three spaces that four gear teeth are missing and 2nd outer baulk ring has three spaces that two gear teeth are missing.
A : 1st outer baulk ring
B : 2nd outer baulk ring
11. Install 3rd main gear (1) to mainshaft with a pressing machine using the inserter (A) [SST: ST30022000 ( - )].
2 : 1st main gear
CAUTION:
Be careful with the orientation of 3rd main gear.
Arrow :1st main gear side
12. Install 3rd-4th main spacer (1) to mainshaft.
13. Install 4th main gear (2) to mainshaft with a pressing machine using the inserter (A) [SST: ST30022000 ( - )].
CAUTION:
Be careful with the orientation of 4th main gear.
Arrow :3rd-4th main spacer side
14. Install mainshaft bearing (1) to mainshaft with a pressing machine using the inserter (A) [SST: ST30911000 ( - )].
CAUTION:
Be careful with the orientation of mainshaft bearing.
Arrow :4th main gear side
15. Install reverse main gear bushing to mainshaft with a pressing machine using the inserter [SST: ST30911000 ( - )].