Mainshaft and Countershaft
1. Clutch hub
2. Synchronizer key
3. Clutch hub sleeve
4. Synchronizer key spring
5. Synchronizer ring (4th)
6. Needle bearing
7. Main drive gear
8. Bearing housing assembly
9. Washer
10. Mainshaft gear assembly
11. Countershaft
12. Counter reverse gear
13. Washer
14. Inner race
15. Needle bearing
16. Reverse gear
17. Synchronizer ring (Reverse)
18. Clutch hub assembly
19. Locknut (Mainshaft)
20. Synchronizer ring (5th)
21. 5th gear
22. Steel ball
23. Thrust lock washer
24. C-washer
25. Retaining ring
26. Mainshaft rear bearing
27. C-washer
28. Retaining ring
29. Washer
30. Snap ring
31. Spacer
32. Counter 5th gear
33. Countershaft rear bearing
34. Locknut (Countershaft)
Assemble in the order shown in the image, referring to Assembly Note.
Assembly note
Mainshaft and countershaft
1. Place the mainshaft gear assembly and the countershaft on the bearing housing.
2. Use a suitable bar to press in the countershaft.
Locknut (Mainshaft)
NOTE: Use pads in the vise to prevent damaging the bearing housing.
1. Secure the bearing housing in a vise.
2. Slide the clutch hub sleeves onto 1st and reverse gears to lock the mainshaft.
3. Tighten a new locknut with the SST.
Tightening torque: 128 - 235 N-m (13 - 24 m-kg, 94 - 174 ft-lb)
4. Use a chisel to crimp the locknut.
Thrust lock washer
1. Insert the steel ball and the thrust lock washer for 5th gear.
CAUTION:
a. Use only 3.0 mm (0.118 in) C-washers, otherwise; it may not be possible to install the rear C-washers.
b. The two C-washers must be the same thickness, or bearing failure will result.
2. Install the C-washers and hold them with the retaining ring.
3. Measure the clearance between the thrust lock washer and C-washers (5th gear end play).
If the end play is not within the standard, adjust it by selecting a thrust lock washer.
Standard play: 0.1 - 0.3 mm (0.004 - 0.012 in)
Thrust lock washer thickness: 6.2 mm (0.244 in), 6.4 mm (0.252 in), 6.5 mm (0.256 in), 6.6 mm (0.260 in)
Mainshaft rear bearing
1. Drive on the mainshaft rear bearing with the SST. Install the C-washers, retaining ring and washer, and secure them with a new snap ring.
2. Measure the clearance between the C-washers and washer. If end play is not within the standard, adjust it by selecting the proper C-washers.
Standard play: 0 - 0.1 mm (0 - 0.004 in)
C-washer thickness: 2.9 mm (0.114 in), 3.0 mm (0.118 in), 3.1 mm (0.122 in), 3.2 mm (0.126 in)
CAUTION: Check to be sure there is no clearance between the mainshaft rear bearing and the C-washers.
Countershaft rear bearing
Drive the countershaft rear bearing onto the countershaft with the SST.
Locknut (Countershaft)
1. Shift the clutch hub sleeves to 1st gear and reverse gear to put the gears in a double-engaged condition.
NOTE: Use pads in the vise to prevent damaging the SST.
2. Connect the SST to the mainshaft and tighten it securely in a vise.
3. Tighten the new locknut.
Tightening torque: 128 - 196 N-m (13 - 20 m-kg, 94 - 145 ft-lb)
4. Use a chisel to crimp the locknut.