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 shaft, then install bearing retainer.




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




3. Install main drive gear bearing.
a. Press in main drive gear bearing.
b. Install main drive gear spacer.

Main Drive Gear Snap Ring:

c. Select proper main drive gear snap ring to minimize clearance of groove.

Allowable clearance of groove:
0 - 0.13 mm (0 - 0.0051 in)

d. Install selected snap ring on main drive gear.










4. Assemble synchronizers.




5. Assemble 2nd main gear, needle bearing and 1st & 2nd synchronizer assembly, then press 1st gear bushing on mainshaft.
6. Install 1st main gear.




7. Install steel ball and thrust washer.
Before installing steel ball end thrust washer, apply grease to them.




8. Press mainshaft assembly to adapter plate with tool.




9. Press counter gear into adapter plate with tool.
10. Install 3rd main gear and then press 3rd & 4th synchronizer assembly.




Note: Pay attention to direction of 3rd & 4th synchronizer.




11. Install thrust washer on mainshaft and secure it with mainshaft front snap ring.
Select proper snap ring to minimize clearance of groove in mainshaft

Mainshaft front snap ring: [1][2]Mechanical Specifications

12. Apply gear oil to mainshaft pilot bearing and install it on mainshaft.




13. Press counter drive gear with main drive gear with tool.




Note: Pay attention to direction of counter drive gear.

Counter Drive Gear Snap Ring:

14. Install sub-gear components.
a. Install sub-gear and sub-gear bracket on counter drive gear and then select proper snap ring to minimize clearance of groove in counter gear.

Allowable clearance of groove: 0 - 0.18 mm (0 - 0.0071 in)




b. Remove snap ring, sub-gear bracket and sub-gear from counter gear.
c. Reinstall sub-gear, sub-gear spring and sub-gear bracket.




15. Install selected counter drive gear snap ring.




16. Press counter gear front bearing onto counter gear.




17. Assemble parts at rear of adapter plate as follows:
a. Install reverse idler gear to reverse idler shaft with spacers, snap rings and needle bearing.




b. Install insert retainer and O.D. synchronizer to mainshaft.

Note: Pay attention to direction of hub.




c. Install O.D. gear bushing with tool.
d. Install O.D. main gear and needle bearing.
e. Install spacer, reverse counter gear and O.D. counter gear.
O.D. main gear and O.D. 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 with tool.




18. Mesh 2nd and reverse gears, then tighten mainshaft lock nut with tool.




Use the left chart when deciding the reading torque.
(Length of torque wrench vs. setting or reading torque)




19. Tighten countershaft lock nut.

Note: Always use new lock nut.

20. Stake mainshaft lock nut and countershaft lock nut with a punch.
21. Measure gear end play. For the description, refer to Disassembly of Gear Components. Gear Components