Mainshaft

Assemble in the reverse order of disassembly, referring to the Assembly Note.

Assembly note




1. Set the 2nd gear and the 1st/2nd clutch hub assembly on the mainshaft, then press in the mainshaft.




2. Set the 3rd gear, needle bearing, and 3rd/4th clutch hub assembly on the mainshaft, then press on the 3rd/4th clutch hub assembly with the SST.




3. Install a new snap ring on the front of the mainshaft.




4. Install the inner race, 1st gear, and thrust washer.




Countershaft
Press the inner race of the countershaft rear bearing onto the countershaft with the SST.

Countershaft front bearing spacer

NOTE: Replace the countershaft front bearing and counter shaft front bearing spacer as one assembly.




1. Install the friction gear, diaphragm spring, and countershaft front bearing spacer.
2. Press the countershaft front bearing spacer onto the countershaft with the SST.

Measurement of Bearing Thrust Play
Mainshaft front bearing




1. Measure the depth of the mainshaft front bearing bore in the rear of the transmission case.




2. Measure the mainshaft front bearing height. The difference between the two measurements indicates the required thickness of the adjustment shim.

Standard thrust play: 0 - 0.1 mm (0 - 0.004 in)
Adjustment shim thickness: 0.1 mm (0.004 in), 0.3 mm (0.012 in)

Countershaft front bearing




1. Measure depth B of the countershaft front bearing bore in the transmission case.




2. Measure the countershaft front bearing snap ring height A.
3. Choose an adjustment shim that will allow the difference between the two measurements to be equal to the standard bearing height.

A - B + Adjustment shim(s) = 0.9 - 1.0 mm (0.035 - 0.039 in)
Standard bearing height on installing: 0.9 - 1.0 mm (0.035 - 0.039 in)
Adjustment shim thickness: 0.1 mm (0.004 in), 0.3 mm (0.012 in)

Transmission case




1. Position the 1st and 2nd shift forks and 3rd and 4th shift forks into the grooves of the clutch hub and sleeve assemblies.
2. Apply molybdenum grease to the needle bearing and install it in the main drive gear.
3. install the main drive gear onto the front of the mainshaft.




4. Set the countershaft gear into the case, making sure that the countershaft gears engage each gear of the mainshaft assembly.

Bearing for transmission case




1. Install the correct shim onto the rear of the mainshaft as determined by "Measurement of Bearing Thrust Play".
2. Drive on the mainshaft front bearing with a suitable pipe.




3. Drive the countershaft center bearing onto the rear of the countershaft with the SST.




4. Install the bearing cover.

Tightening torque: 18 - 26 N-m (1.8 - 2.7 m-kg, 13 - 20 ft-lb)




5. Install the SST between the 4th synchronizer ring and synchromesh gear on the main drive gear.




6. Drive on the main drive gear bearing with the SST.




7. Install a new snap ring to secure the main drive gear bearing.

NOTE: Replace the countershaft front bearing and counter- shaft front bearing spacer as one assembly.




8. Install the correct shim into the countershaft front bearing as determined by "Measurement of Bearing Thrust Play".
9. Drive on the countershaft front bearing with the SST.

NOTE: Do not confuse the front and rear bearing snap rings. The countershaft front snap ring is smallest.




10. Install a new snap ring to secure the countershaft front bearing.