Assembly Procedure

Assembly method for triple cone assembly to 1st speed gear side





1. Assemble the synchronizer inner ring to the 1st speed gear.





2. Assemble the synchronizer cone onto the synchronizer ring. Align 6 lugs on the cone with the 6 holes in the 1st speed gear.





3. Assemble the synchronizer outer ring and the synchronizer spring (1st gear side outer ring has one punch mark as shown).

NOTE:
The waved synchronizer spring is flattened and acts as a synchronizer key when installed.





4. Assemble the synchronizer outer ring onto the 1st speed gear. When installing, align the grooves in the synchronizer inner ring with the grooves in the outer ring.

Assembly method for synchronizer hub and sleeve





5. Locate 3 low teeth on the synchronizer hub:

The 3 low teeth "B" are not marked with black as shown in the photograph. They must be identified by counting 9-teeth in any direction (midway) between the "A" slots.

NOTE:
The depressed side of the hub and the thin side of the sleeve should face the 1st gear side, and the protruded side of the hub and the thick side of the sleeve should face the 2nd gear side (see photo).





6. Locate 3 high sets of two consecutive chamfered teeth "C" on the synchronizer sleeve.





7. Install synchronizer hub into synchronizer sleeve (follow previous note): Align 3 low teeth "B" (identified in step 5) with 3 high sets of two consecutive chamfered teeth "C" (identified in step 6).





8. Assemble the synchronizer hub and sleeve (assembled in step 7) with the 1st speed gear and triple cone synchronizer (assembled in step 4) as shown in the photo.

NOTE:
Align 3 lugs in the synchronizer outer ring with 3 grooves in the synchronizer hub.





Completed sub-assembly

Assembly method for triple cone assembly to 2nd speed gear side





9. Assemble the synchronizer inner ring to the 2nd speed gear.





10. Assemble the synchronizer cone onto the synchronizer ring. Align 6 lugs on the cone with the 6 holes in the 2nd speed gear.





11. Assemble the synchronizer outer ring and the synchronizer spring (2nd gear side outer ring has two punch marks as shown).

NOTE:
The waved synchronizer spring is flattened and acts as a synchronizer key when installed.





12. Assemble the synchronizer outer ring onto the 2nd speed gear. When installing, align the grooves in the synchronizer inner ring with the grooves in the outer ring.





13. Install the 2nd gear assembly (assembled in step 12) onto the subassembly completed in step 8.

NOTE:
Align 3 lugs on the synchronizer outer ring with the 3 slots "A" in the hub (see step 5 for "A" slots).





Completed assembly of 1st and 2nd speed gears