Mainshaft and Countershaft

1. Mainshaft
2. Bearing
3. 2nd gear
4. Inner cone
5. Double cone
6. Synchronizer ring
7. Synchronizer assembly (2nd)
8. 1st/2nd clutch hub
9. Synchronizer key
10. Clutch hub sleeve
11. Synchronizer key spring
12. 1st/2nd clutch hub assembly
13. 3rd gear
14. Bearing
15. Inner cone
16. Double cone
17. Synchronizer ring
18. Synchronizer assembly (3rd)
19. 3rd/4th clutch hub
20. Synchronizer key
21. Clutch hub sleeve
22. Synchronizer key spring
23. 3rd/4th clutch hub assembly
24. Synchronizer ring
25. Synchronizer ring (1st)
26. Bearing race
27. Bearing
28. 1st gear
29. Countershaft
30. Countershaft center bearing race
31. Countershaft front bearing spacer

Assemble in the order shown, referring to Assembly Note

Assembly note




Synchronizer assembly (2nd, 3rd)

NOTE: The 1st and 2nd synchronizer rings can be easily distinguished by noting that the 1st synchronizer ring has two teeth fused together at three equally spaced places around its outer edge. The 2nd synchronizer ring has no distinguishing marks.

Install the inner cone, double cone, and synchronizer ring as shown in the image.




Clutch hub assembly (1st/2nd, 3rd/4th)

CAUTION:
- Align the synchronizer ring grooves (2nd, 3rd) with the synchronizer keys during installation.
- Align the slots in the clutch hub with the tabs on the inner cone.




- Align the synchronizer ring grooves (1st, 4th) with the synchronizer keys.









NOTE: Standard key dimensions are as follows:






CAUTION: Press each clutch hub assembly onto the mainshaft in the proper direction as shown.






CAUTION:
- Do not damage parts while using the press.
- Install the double cone pegs into the holes in the flank side of the gear as shown in the image.




1. Set the needle bearing, 2nd gear, synchronizer assembly (2nd), and the 1st/2nd clutch hub assembly on the mainshaft, then press in the mainshaft.




2. Set the needle bearing, 3rd gear, synchronizer assembly (3rd), and 3rd/4th clutch hub assembly on the main- shaft, then press them onto the mainshaft by using the SST.




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

Countershaft center bearing race





Press the countershaft center bearing race onto the countershaft by using the SST.




Countershaft front bearing spacer

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

Install the countershaft front bearing spacer.