Gear Components

1. Install bearings into case components.




2. Assemble adapter plate parts.
- Install oil gutter on adapter plate and expand on rear side.




- Install bearing retainer.
a. Insert reverse shaft, then install bearing retainer.




b. Tighten each screw, then stake each at two points.




3. Install main drive gear bearing.
a. Press main drive gear bearing.
b. Install main drive gear spacer.




c. Select proper main drive gear snap ring to minimize clearance of groove and install it.
Allowable clearance of groove: 0 - 0.13 mm (0 - 0.0051 in)




4. Assemble synchronizers.
- 1st & 2nd synchronizer










- Check coupling sleeve and synchronizer hub orientation.




- 3rd & 4th synchronizer




- O.D. synchronizer




5. Install front side components on main shaft.
a. Assemble 2nd main gear, needle bearing and 1st & 2nd synchronizer assembly, then press 1st gear bushing on mainshaft.
b. Install 1st main gear.




c. Install steel ball and 1st gear washer.
- Apply multi-purpose grease to steel ball and 1st gear washer before installing.




6. Install mainshaft and counter gear on adapter plate and main drive gear on mainshaft.
a. Press mainshaft assembly to adapter plate with Tool.




b. Press counter gear into adapter plate with Tool.
c. Install 3rd main gear and then press 3rd & 4th synchronizer assembly.




- Pay attention to direction of 3rd & 4th synchronizer.




d. Install thrust washer on mainshaft and secure it with mainshaft front snap ring.
Select proper snap ring to minimize clearance of groove in mainshaft.
Allowable clearance of groove: 0 - 0.18 mm (0 - 0.0071 in)
e. Apply gear oil to mainshaft pilot bearing and install it on mainshaft.




f. Press counter drive gear with main drive gear with Tool.




- Pay attention to direction of counter drive gear.




g. Install sub-gear components.
1. Install sub-gear and sub-gear bracket on counter drive gear and then select proper snap ring to minimize clearance of groove in counter gear.
Allowable clearance of groove: 0 - 0.18 mm (0 - 0.0071 in)
2. Remove snap ring, sub-gear bracket and sub-gear from counter gear.
3. Reinstall sub-gear, sub-gear spring and sub-gear bracket.




h. Install selected counter drive gear snap ring.




i. Press counter gear front bearing onto counter gear.




7. Install rear side components on mainshaft and counter gear.
a. Install reverse idler gear to reverse idler shaft with spacers, snap rings and needle bearing.




b. Install insert retainer and O.D. synchronizer to mainshaft.
- Pay attention to direction of hub.




c. Install O.D. gear bushing with Tool.
d. Install O.D. main gear and needle bearing.
e. Install spacer, reverse counter gear and O.D. counter gear.
- O.D. main gear and O.D. counter gear should be handled as a matched set.
f. Install washer, roller bearing, steel roller and thrust washer.
g. Tighten mainshaft lock nut temporarily.
- Always use new lock nut.




h. Install countershaft rear end bearing with Tool.




8. Mesh 2nd and reverse gears, then tighten mainshaft lock nut with Tool.




- Use the left chart when deciding the reading torque. (Length of torque wrench vs. setting or reading torque)
9. Tighten countershaft lock nut.
- Always use new lock nut.




10. Stake mainshaft lock nut and countershaft lock nut with a punch.
11. Measure gear end play.