Step 2
NOTE:a. Wash all parts.
b. Apply oil to all friction surfaces.
c. Use new roll pins and retaining rings.
STEP 2
NOTE: During assembly, check the thrust clearance of each gear.
Assembly
Specification:
Install the synchronizer key spring in the clutch hub with the hook in the groove. This holds the three synchronizer keys in place.
NOTE: The sizes of the synchronizer keys are different.
Primary Shaft
1. Install the new bearing inner race with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
2. Install the 3rd gear, synchronizer ring, and clutch hub assembly with the SST.
NOTE:
a. Press to 19,620 N (2,000 kg, 4,400 lb).
b. Align the synchronizer ring groove and clutch housing hub key when installing.
3. Install the retaining ring.
4. Install the synchronizer ring, 4nd gear, and bearing inner race with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
5. Install both shift forks and the interlock sleeve, as in the image.
6. Measure the clearance between the 3rd gear and 2nd gear.
Clearance: 0.05-0.20 mm (0.0020-0.0079 in)
Maximum: 0.25 mm (0.0098 in)
7. Measure the clearance between the 4th gear and bearing inner race.
Clearance: 0.165-0.365 mm (0.0064-0.0144 in)
Maximum: 0.415 mm (0.0163 in)
8. Install the new bearing, inner race with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
NOTE: The styles and sizes of synchronizer rings are different as shown in the illustration.
Secondary Shaft
1. Assemble the 1st gear, synchronizer ring, and clutch hub assembly (reverse gear), as shown in the image.
NOTE: Align the synchronizer ring, groove and clutch housing hub key when installing.
2. Press on the clutch hub assembly (reverse gear) with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
3. Install the retaining ring.
4. Install the synchronizer ring and 2nd gear.
5. Install the secondary 3rd gear with the SST.
NOTE: Press to 19,620 N (2,000 kg, 4,400 lb).
6. Install the retaining ring.
7. Install the secondary 4th gear and new bearing inner race.
8. Measure the clearance between the 1st gear and differential drive gear.
Clearance: 0.05-0.28 mm (0.0020-0.0110 in)
Maximum: 0.33 mm (0.0199 in)
9. Measure the clearance between the 2nd gear and secondary 3rd gear.
Clearance: 0.175-0.455 mm (0.0069-0.0179 in)
Maximum: 0.505 mm (0.0199 in)