Assembly

1. Lubricate output shaft journals, gears and needle bearings with recommended gear lubricant.





2. Install third gear and needle bearing on shaft.
3. Install synchro ring on third gear.





4. Assemble 1-2 and 3-4 synchro hubs and sleeves.





5. Install inserts and springs in synchro sleeves. Position open ends of springs 180° apart as shown.
6. Install 3-4 synchro hub and sleeve on output shaft. Press hub onto shaft if necessary.





7. Install 3-4 synchro hub snap ring. Use thickest snap ring that will fit in shaft groove.





8. Verify third gear thrust clearance with feeler gauge. Clearance should be 0.10 to 0.25 mm (0.004 to 0.010 inch).
9. Lubricate remaining output shaft gears and bearings with gear lubricant.





10. Install second gear and needle bearing on shaft.
11. Install synchro ring on second gear.
12. Assemble first/reverse hub, insert springs, inserts, reverse gear and 1-2 sleeve. Be sure spring ends are 180° apart. Note that splines in hub bore are chamfered on one side. Install hub so chamfered side faces front of output shaft.
13. Press assembled hub and sleeve on output shaft.
14. Install selective snap ring. Use thickest snap ring that will fit in output shaft groove.





15. Install synchro ring on first gear.
16. Install first gear spacer on shaft and against selective fit snap ring.
17. Install first gear and needle bearing on output shaft.
18. Install locating pin and thrust washer on shaft.
19. Press rear bearing on shaft. Position bearing snap ring groove so it is closest to end of output shaft.





20. Check first and second gear thrust clearance with feeler gauge.
- First gear clearance should be 0.10 to 0.40 mm (0.003 to 0.0197 inch)
- Second gear clearance should be 0.10 to 0.30 mm (0.003 to 0.0118 inch)





21. Press fifth gear onto output shaft. Then install select fit snap ring. Use thickest snap ring that will fit in shaft groove.





22. Lubricate input shaft pilot bearing with petroleum jelly and install bearing in shaft.





23. Install input shaft on output shaft. Be sure output shaft hub is fully seated in pilot bearing.