Part 2

Assembling, through Transmission Build Date 25 October 2009

Checking the Inner Race for 1st, 2nd and 3rd Gear for Wear





- Check the tabs on the inner race for scoring.

- Install the inner race onto taper of selector gear and then measure gap dimension - a - with a feeler gauge.






Checking the 1st, 2nd and 3rd Gear Synchronizer Rings for Wear





- Install the synchronizer ring, outer race and inner race onto taper of selector gear and then measure the gap dimension - a - with a feeler gauge.






- Install the 2nd gear with the needle bearing.

Installed Position: 2nd Gear Outer Race, Inner Race and Synchronizer Ring





- Check the tabs - arrows 1 and 2 - for scoring.

- Replace the inner race, the outer race and the synchronizer ring if they have grooves or scoring.

- Install the inner race - A - on the 2nd gear.

The angled tabs - arrows 1 - face the outer race - B -.

- Install the outer race - B -.

The tabs - arrows 2 - must lock into the retainers - arrows 3 - in the gear.

- Install the synchronizer ring - C -.

The retainers - arrows 4 - lock in the tabs - arrows 1 - on the inner race - A -.

Disassembling and Assembling the Locking Collar and the Synchronizer Hub for 1st, 2nd, 3rd and 4th Gears





1. Spring

2. Locking piece

3. Locking collar

4. Synchronizer hub


- Slide the locking collar over the synchronizer hub.

In 3rd and 4th gear, the wide collar on the synchronizer hub and the locking collar face in one direction.

The notches for the locking pieces on the synchronizer hub and locking collar must line up with each other.

Assembly: Locking Collar/Synchronizer Hub for 1st, 2nd, 3rd and 4th Gears





The locking collar is pushed over the synchronizer hub.

- Install the locking pieces and springs offset by 120°. The angled end of the spring must engage into the hollow locking piece.

Installed Position: Locking Collar/Synchronizer Hub for 1st and 2nd Gears





The identification groove - arrow 1 - and the narrow collar - arrow 2 - on the synchronizer hub face 1st gear.

Installing the Locking Collar/Synchronizer Hub for 1st and 2nd Gears





Turn the synchronizer ring so that the grooves line up with the locking pieces.

- Install the locking ring.

Install the synchronizer ring for 1st gear.

Installed Position of the 1st Gear Outer race





The tabs - arrows - face the synchronizer hub/locking collar - A -.

Installed Position: Synchronizer Ring - A - (1st Gear Inner Race)





The tabs - arrows 1 - engage into the holes - arrows 2 - inside the synchronizer ring - B -.

Install 1st Gear with Needle Roller Bearing





The higher collar - A - faces 2nd gear - B -. The notches in the collar - arrow - lock into the tabs on the outer race. Refer to => [ Installed Position of the 1st Gear Outer race ].

- Install the thrust washers for 1st and 4th gears => [ (Item 19) Thrust Washer ] Output Shaft, 1st to 4th Gears Overview and => [ (Item 20) Washer ] Output Shaft, 1st to 4th Gears Overview.

- Install 4th gear with the needle bearing.

- Press the synchronizer ring onto the taper of the gear and measure the gap dimension - a - using a feeler gauge.






Installed Position: Locking Collar/Synchronizer Hub for 3rd and 4th Gears





The wider collar on the synchronizer hub - arrow - faces 3rd gear.

Installing the Synchronizer Hub with Locking Collar for 3rd and 4th Gears





- Turn the synchronizer ring so that the grooves line up with the locking pieces.

- Install the locking ring.

- Install the 3rd gear synchronizer ring on the synchronizer hub/locking collar for 3rd and 4th gears.

Installed Position: 3rd Gear Outer Race





The tabs - arrows - face the synchronizer hub/locking collar - A -.

Installed Position: Synchronizer Ring - A - (3rd Gear Inner Race)





The tabs - arrows 1 - engage into the holes - arrows 2 - inside the synchronizer ring - B -.

Installed Position: 3rd Gear





The higher collar - A - faces toward 4th gear - B -. The notches in the collar - arrow - lock into the tabs on the outer race. Refer to => [ Installed Position of the 1st Gear Outer race ].

- Install the 3rd gear wheel with the needle bearing.

• Pressing on the inner race/tapered roller bearing. Refer to => [ Installing the Inner Race/Tapered Roller Bearing on the Side of the Transmission Housing ].

• Selecting the locking ring for the inner race/tapered roller bearing. Refer to => [ Selecting the Locking Ring ].