Assembly

1. If front bearing was removed from input shaft, press new bearing on shaft.
2. Secure front bearing with thickest snap ring that will fit in groove.





3. Press front bearing on counter gear. Secure bearing with thickest snap ring that will fit in ring groove.





4. Install new oil seals in front bearing retainer and adapter. Bearing retainer seal depth is 11.2 - 12.1 mm (0.441 - 0.480 inch).





5. Install reverse shaft and shaft retaining pin in adapter. Then install access hole plug with torx bit.
6. Lubricate transmission components with specified gear lubricant.





7. Assemble 1-2 and 3-4 synchronizer hubs, sleeves, springs and key inserts.





8. Assemble and install third gear, needle bearing, synchronizer ring, 3-4 synchronizer and snap ring on output shaft. Use thickest snap ring that fits in shaft groove.





9. Verify third gear thrust clearance with feeler gauge. Clearance should be 0.10 - 0.25 mm (0.004 - 0.010 inch).





10. Assemble second gear, gear needle bearing, synchronizer ring and 1-2 synchronizer. Then press assembly on output shaft.





11. Install first gear lock ball in output shaft.





12. Assemble first gear, synchronizer ring, gear needle bearing and inner race. Then install assembly on output shaft. Rotate inner race until aligned with locking ball.





13. Press rear bearing on shaft. Snap ring groove in bearing goes toward rear. Use screwdriver to hold inner race in position when installing bearing.
14. Install snap ring on rear bearing.





15. Check first-second gear thrust clearance. Standard clearance is 0.10 - 0.25 mm (0.004 - 0.010 inch).





16. Press fifth gear on output shaft.





17. Install fifth gear snap ring. Use thickest snap ring that will fit in shaft groove.





18. Lubricate input shaft roller bearings with petroleum jelly and install rollers in shaft.





19. Install output shaft assembly in intermediate plate. Tap plate with mallet and pull on shaft to seat.
20. Install input shaft on output shaft.





21. Install counter gear in intermediate plate.





22. Install rear bearing snap ring and install bearing retainer. Tighten retainer screws to 18 Nm (13 ft. lbs.) torque.





23. Install reverse shift arm. Tighten attaching bolt to 18 Nm (13 ft. lbs.) torque.





24. Assemble counter fifth gear and synchro components.





25. Install lock ball, spacer and needle bearing on counter shaft.





26. Install assembled gear and synchronizer on counter shaft.





27. Install remaining synchronizer ring and spline fifth gear. Use length of pipe to tap gear into place.





28. Shift 1-2 and 3-4 synchronizer sleeves into gear to lock output shaft and counter gear.





29. Install fifth gear snap ring.
30. Disengage 1-2 and 3-4 synchronizer sleeves.
31. Check counter fifth gear thrust clearance. Standard clearance is 0.10 - 0.30 mm (0.004 - 0.010 inch). Adjust clearance with different thickness snap ring it necessary.