Part 1

ASSEMBLY
Gear Components
1. Install 5th-6th synchronizer hub assembly according to the following.
a. Install 5th-6th coupling sleeve to 5th-6th synchronizer hub.





CAUTION:
^ Do not reuse 5th-6th synchronizer hub and 5th-6th coupling sleeve.
^ Replace 5th-6th synchronizer hub and 5th-6th coupling sleeve as a set.
^ Be careful with the orientation 5th-6th coupling sleeve.





^ Be careful with the orientation 5th-6th synchronizer hub.





b. Install shifting inserts and spread springs to 5th-6th synchronizer hub.

CAUTION:
^ Do not install spread spring hook onto the same shifting insert.





^ Be careful with the shape of reserve shifting insert to avoid misemploy.





c. Press in 5th-6th synchronizer hub assembly, 6th baulk ring, 6th main gear and 6th needle bearing using the inserter.

CAUTION:
^ Apply gear oil to 6th baulk ring and 6th needle bearing.
^ Be careful with the orientation 5th-6th coupling sleeve.





NOTE: 5th and 6th baulk rings have three spaces that four gear teeth are missing as shown in the figure.





2. Select and install a snap ring so that the end play comes within the standard value. Refer to "Snap Rings".
End play: 0 - 0.10 mm (0 - 0.004 inch)

CAUTION: Do not reuse snap ring.

3. Install 1st-2nd synchronizer hub assembly according to the following.
a. Install 1st-2nd coupling sleeve to 1st-2nd synchronizer hub.





CAUTION:
^ Do not reuse 1st-2nd coupling sleeve and 1st-2nd synchronizer hub.
^ Replace 1st-2nd synchronizer hub and 1st-2nd coupling sleeve as a set.
^ Be careful with the orientation 1st-2nd coupling sleeve.





^ Be careful with the orientation 1st-2nd synchronizer hub.





b. Install spread springs and shifting inserts to 1st-2nd synchronizer hub.

CAUTION:
^ Do not install spread spring hook onto the same shifting insert.





^ Be careful with the shape of reverse shifting insert to avoid misassembly.





c. Press in 1st-2nd synchronizer hub assembly, 2nd inner baulk ring, 2nd synchronizer cone and 2nd outer baulk ring, 2nd main gear and 2nd needle bearing using the support ring.

CAUTION:
^ Apply gear oil to 2nd needle bearing, 2nd inner baulk ring, 2nd synchronizer cone and 2nd outer baulk ring, 1st-2nd synchronizer hub spline of mainshaft.
^ Replace 2nd inner baulk ring, 2nd synchronizer cone and 2nd outer baulk ring as a set.
^ Be careful with the orientation 1st-2nd coupling sleeve.





NOTE: 1st outer baulk ring has three spaces that three gear tooth is missing and 2nd outer baulk ring has three spaces that two gear teeth are missing.





4. Press in 1st gear bushing using the support ring.
5. Install 1st outer baulk ring, 1st synchronizer cone, 1st inner baulk ring, 1st needle bearing and 1st main gear to mainshaft.

CAUTION:
^ Apply gear oil to 1st outer baulk ring, 1st synchronizer cone, 1st inner baulk ring and 1st needle bearing.
^ Replace 1st outer baulk ring, 1st synchronizer cone and 1st inner baulk ring as a set.





NOTE: 1st outer baulk ring has three spaces that three gear tooth is missing and 2nd outer baulk ring has three spaces that two gear teeth are missing.





6. Press in 3rd main gear using the inserter.

CAUTION:
^ Do not reuse 3rd main gear.
^ Be careful with the orientation 3rd main gear.





7. Install 3rd-4th main spacer to mainshaft.
8. Press in 4th main gear using the inserter.

CAUTION:
^ Do not reuse 4th main gear.
^ Be careful with the orientation 4th main gear.





9. Press in mainshaft bearing using the inserter.

CAUTION: Be careful with the orientation mainshaft bearing.





10. Press in reverse main gear bushing using the inserter.





11. Press in 3rd gear bushing using the inserter.
12. Install 3rd-4th synchronizer hub assembly according to the following.
a. Install 3rd-4th coupling sleeve to 3rd-4th synchronizer hub.

CAUTION:
^ Do not reuse 3rd-4th synchronizer hub and 3rd-4th coupling sleeve.
^ Replace 3rd-4th synchronizer hub and 3rd-4th coupling sleeve as a set.





^ Be careful with the orientation 3rd-4th coupling sleeve.





b. Install spread springs and shifting inserts to 3rd-4th synchronizer hub.

CAUTION:
^ Do not install spread spring hook onto the same shifting insert.





^ Be careful with the shape of reverse shifting insert to avoid misassembly.





c. Press in 3rd-4th synchronizer hub assembly, 3rd inner baulk ring, 3rd synchronizer cone, 3rd outer baulk ring, 3rd counter gear and 3rd needle bearing using the inserter.

CAUTION:
^ Apply gear oil to 3rd inner baulk ring, 3rd synchronizer cone, 3rd outer baulk ring and 3rd needle bearing, hole spline of 3rd-4th synchronizer hub.
^ Replace 3rd inner baulk ring, 3rd synchronizer cone and 3rd outer baulk ring as a set.
^ Be careful with the orientation 3rd-4th coupling sleeve.





NOTE: 4th baulk ring has three spaces that one gear tooth is missing but 3rd baulk ring doesn't.





13. Press in 4th counter gear thrust washer, 4th gear bushing, 4th needle bearing, 4th counter gear, 4th outer baulk ring, 4th synchronizer cone and 4th inner baulk ring using the inserter.

CAUTION:
^ Apply gear oil to 4th needle bearing, 4th outer baulk ring, 4th synchronizer cone and 4th inner baulk ring.
^ Replace 4th outer baulk ring, 4th synchronizer cone and 4th inner baulk ring as a set.
^ Be careful with the orientation 4th counter gear thrust washer.





NOTE: 4th baulk ring has three spaces that one gear tooth is missing but 3rd baulk ring doesn't.





14. Press in counter rear bearing inner race using the inserter.

CAUTION: Be careful with the orientation counter rear bearing inner race.





15. Install main drive gear bearing according to the following.
a. Press in main drive gear bearing using the drift.

CAUTION: Be careful with the orientation main drive gear bearing.





b. Select and install a snap ring to main drive gear bearing so that the end play comes within the standard value. Refer to "Snap Rings".
End play: 0 - 0.10 mm (0 - 0.004 inch)

CAUTION: Do not reuse snap ring.





16. Install breather to adapter plate.

CAUTION:
^ Do not reuse breather.
^ Be careful with the orientation breather.





17. Install magnet to adapter plate.

CAUTION: Be careful with the orientation magnet.





18. Install baffle plate to adapter plate, and then tighten mounting bolt to the specified torque. Refer to "Case Components".
19. Install main drive gear assembly, mainshaft assembly and counter gear assembly according to the following





a. Install main pilot bearing, pilot bearing spacer and 5th baulk ring to main drive gear.
b. Install main drive gear assembly, mainshaft assembly and counter gear assembly combined in one unit to adapter plate using brass bar.





20. Install adapter setting plate to adapter plate, and then fixing in adapter setting plate using a vise.

CAUTION: Do not directly secure mating surface of adapter plate in a vice.





21. Install snap ring to mainshaft bearing.

CAUTION: Do not reuse snap ring.





22. Install counter rear bearing to adapter plate using the drift.
23. Install counter rear bearing spacer to counter gear.

CAUTION: When installing counter rear bearing spacer, groove should face to the rear side.

24. Install bearing retainer according to the following.
a. Install bearing retainer to adapter plate.





b. Apply recommended thread locking sealant to threads of bolts, and then tighten mounting bolts to the specified torque. Refer to "Case Components".
^ Use Genuine Medium Strength Thread Locking Sealant or the equivalent. Refer to "Recommended Chemical Products and Sealants".
25. Install reverse synchronizer hub assembly according to the following.
a. Install reverse coupling sleeve to reverse synchronizer hub.

CAUTION:
^ Do not reuse reverse coupling sleeve and reverse synchronizer hub.
^ Replace reuse reverse coupling sleeve and reverse synchronizer hub as a set.





^ Be careful with the orientation reverse coupling sleeve.





^ Be careful with the orientation reverse synchronizer hub.





b. Install spread springs to shifting inserts to reverse synchronizer hub.

CAUTION:
^ Do not install spread spring hook onto the same shifting insert.





^ Be careful with the shape of 1st-2nd, 3rd-4th and 5th-6th shifting insert to avoid misassembly.





c. Install snap ring to reverse synchronizer hub.

CAUTION:
^ Do not reuse snap ring.
^ Do not align the snap ring notch with synchronizer hub groove when assembling.





d. Press in reverse synchronizer hub assembly, reverse baulk ring, reverse main gear and reverse main needle bearing using the drift and press plate.

CAUTION: Apply gear oil to reverse baulk ring and reverse main needle bearing.





NOTE: Reverse baulk ring has three spaces that two gear teeth are missing, and each space has small ditch for identification as shown in the figure.





26. Select and install a snap ring so that the end play comes within the standard value. Refer to "Snap Rings".
End play: 0 - 0.10 mm (0 - 0.004 inch)

CAUTION: Do not reuse snap ring.





27. Press in reverse counter gear using the drift.

CAUTION:
^ Do not reverse counter gear.
^ Be careful with the orientation counter gear.





28. Select and install a snap ring so that the end play comes within the standard value. Refer to "Snap Rings".
End play: 0 - 0.10 mm (0 - 0.004 inch)

CAUTION: Do not reuse snap ring.

29. Install reverse idler shaft assembly according to the following.
a. Install reverse idler needle bearing, reverse idler gear and reverse idler thrust washer to reverse idler shaft.

CAUTION: Apply gear oil to reverse idler needle bearing.





b. Install reverse idler shaft assembly to adapter plate.

Shift Control Components





1. Install main drive gear assembly, mainshaft assembly, counter gear assembly and reverse idler shaft assembly. Refer to "Gear Components".
2. Install striking rod assembly according to the following.
a. Install striking rod assembly to adapter plate.





b. Install stopper ring to striking rod assembly.
c. Install retaining pin onto stopper ring using a pin punch.

CAUTION: Do not reuse retaining pin.





3. Install 5th-6th fork rod (reversal side) according to the following.
a. Install 5th-6th shift fork to 5th-6th coupling sleeve.
b. Install 5th-6th fork rod (reversal side) to 5th-6th shift fork.
c. Install retaining pin onto 5th-6th shift fork using a pin punch.

CAUTION: Do not reuse retaining pin.





4. Install 5th-6th control lever to adapter plate, and then tighten mounting bolts to the specified torque. Refer to "Shift Control Components".

CAUTION: Install 5th-6th control lever with projection side at upward.





5. Install 5th-6th fork rod according to the following.
a. Install 5th-6th fork bracket and 5th-6th fork rod to adapter plate.
b. Install retaining pin onto 5th-6th fork bracket using a pin punch.

CAUTION: Do not reuse retaining pin.





6. Install check balls to adapter plate.

CAUTION: Apply gear oil to check balls.





7. Install reverse fork rod according to the following.
a. Install reverse shift fork to reverse coupling sleeve.
b. Install reverse fork rod to reverse shift fork.
c. Install retaining pin onto reverse shift fork using a pin punch.

CAUTION: Do not reuse retaining pin.





8. Install interlock pin and interlock plunger to adapter plate.

CAUTION: Apply gear oil to interlock pin and interlock plunger.





9. Install 1st-2nd fork rod according to the following.
a. Install 1st-2nd shift fork to 1st-2nd coupling sleeve.
b. Install 1st-2nd fork rod to 1st-2nd shift fork.
c. Install retaining pin onto 1st-2nd shift fork using a pin punch.

CAUTION: Do not reuse retaining pin.





10. Install interlock pin and check balls to adapter plate.

CAUTION: Apply gear oil to interlock pin and check balls.





11. Install 3rd-4th fork rod (reversal side) according to the following.
a. Install 3rd-4th shift fork to 3rd-4th coupling sleeve.
b. Install 3rd-4th fork rod (reversal side) to 3rd-4th shift fork.
c. Install retaining pin onto 3rd-4th shift fork using a pin punch.

CAUTION: Do not reuse retaining pin.





12. Install 3rd-4th fork rod according to the following.
a. Install 3rd-4th fork rod to adapter plate.
b. Install 3rd-4th fork rod bracket to 3rd-4th fork rod.
c. Install retaining pin onto 3rd-4th fork rod bracket using a pin punch.

CAUTION: Do not reuse retaining pin.





13. Install 3rd-4th control lever according to the following.





a. Install shifter cap to 3rd-4th control lever.
b. Install 3rd-4th control lever to adapter plate, and then tighten mounting bolts to the specified torque. Refer to "Shift Control Components".

CAUTION: Be careful with the orientation 3rd-4th control lever.

14. Install check ball plug according to the following.
a. Install check balls, check ball springs to adapter plate.

CAUTION: Apply gear oil to check ball.

b. Apply recommended sealant to threads of check ball plugs, and tighten check ball plugs to the specified torque. Refer to "Shift Control Components".
^ Use Genuine Silicone RTV or the equivalent. Refer to "Recommended Chemical Products and Sealants".





15. Install baffle plate to adapter plate, and then tighten mounting bolt to the specified torque. Refer to "Case Components"