FREE REPAIR MANUALS & LABOR GUIDES 1982-2013 Vehicles
Courtesy of Operation CHARM: Car repair manuals for everyone.

Gear Components






1. Install bearings into case components.





2. Assemble adapter plate parts.
- Install oil gutter on adapter plate and expand on rear side.
- Install bearing retainer.
a. Insert reverse idler shaft, then install bearing retainer.





b. Tighten each screw, then stake each one at two points.





3. Install main drive gear ball bearing.
a. Press main drive gear ball bearing.





b. Select and install proper main drive gear snap ring to achieve proper clearance of groove.





- Allowable clearance of groove: 0 - 0.13 mm (0 - 0.0051 inch)
- Refer to the illustration for main drive gear snap ring availability.
4. Assemble synchronizers.





- Check coupling sleeve and synchronizer hub orientation.








- 2nd double baulk ring type synchronizer.





- 3rd & 4th synchronizer
- The three synchronizer gutters should be at the rear.





- Overdrive & reverse synchronizer.





5. Assemble front side components to mainshaft.
a. Install 2nd main gear, needle bearing and 1st & 2nd synchronizer assembly, then press 1st gear bushing on mainshaft.
b. Install 1st main gear.





c. Install steel ball and 1st gear washer.
- Before installation, apply multi-purpose grease to steel ball and to both sides of the 1st gear washer.





6. Install mainshaft and counter gear on adapter plate and main drive gear on mainshaft as follows:
a. Press mainshaft assembly into adapter plate using Tool.





b. Press counter gear into adapter plate using Tool.
c. Install 3rd main gear and needle bearing, then press 3rd & 4th synchronizer assembly onto mainshaft.
- Pay attention to the direction of 3rd & 4th synchronizer.





d. Install front mainshaft snap ring. Select proper front mainshaft snap ring to achieve proper clearance of groove.

Available Snap Rings For Mainshaft (front):





- Allowable clearance of groove: 0 - 0.18 mm (0 - 0.0071 inch)
- Refer to the illustration for mainshaft front snap ring availability.
e. Apply gear oil to mainshaft pilot bearing and install it on mainshaft.





f. Press counter drive gear together with main drive gear using Tool.
- Pay attention to the direction of counter drive gear.





g. Install sub-gear components.
(1) Install sub-gear and sub-gear bracket on counter drive gear, then select proper snap ring to achieve proper clearance of groove.

Available Snap Rings For Counter Drive Gear:





- Allowable clearance of groove: 0 - 0.18 mm (0 - 0.0071 inch)
- Refer to the illustration for counter drive gear snap ring availability.
(2) Remove snap ring, sub-gear bracket and sub-gear from counter gear.
(3) Reinstall sub-gear, sub-gear spring and sub-gear bracket.





h. Install selected counter drive gear snap ring.





i. Press countershaft front bearing onto counter gear using Tool.





7. Install rear side components on mainshaft and counter gear as follows:
a. Install reverse idler gear to reverse idler shaft along with spacers, snap rings and reverse idler gear bearing.





b. Install bushing, reverse main gear and overdrive & reverse synchronizer to mainshaft.
- Pay attention to the direction of synchronizer hub.





c. Install overdrive gear bushing to mainshaft using Tool.
d. Install overdrive main gear and needle bearing to mainshaft.
e. Install spacer, reverse counter gear and overdrive counter gear to countershaft.
- OD main gear and OD counter gear should be handled as a matched set.
f. Install washer, roller bearing, steel roller and thrust washer.
g. Tighten mainshaft lock nut temporarily.
- Always use new lock nut.





h. Install countershaft rear end bearing using Tool.





8. Mesh 2nd and reverse gears, then tighten mainshaft lock nut to 137 - 167 Nm (101 - 123 ft. lbs.) using Tool.
- Always use new lock nut.





- Use the chart shown to determine the proper reading torque. (Length of torque wrench vs. setting or reading torque)
9. Tighten countershaft lock nut to 98 - 127 Nm (72 - 94 ft. lbs.).
- Always use new lock nut.





10. Stake mainshaft lock nut and countershaft lock nut using a punch.
11. Measure gear end play.