Disassembly and Assembly

DISASSEMBLY

Gear End Play:

1. Before disassembly, check 3rd, 4th and 5th input gear end plays.
- If not within specification, disassemble and check contact surface of gear, shaft and hub. Then check clearance of snap ring and thrust washer. Refer to "Assembly" below.




2. Remove input shaft rear bearing.




3. Remove 5th & reverse synchronizer and 5th input gear.




4. Remove thrust washer ring, thrust washers and 4th input gear.




5. Remove snap ring.




6. Remove 3rd & 4th synchronizer and 3rd input gear.




7. Remove input shaft front bearing.

ASSEMBLY







1. Place inserts in three grooves on coupling sleeve (3rd & 4th synchronizer).







2. Install 3rd input gear and 3rd baulk ring.
3. Press on 3rd & 4th synchronizer hub.

Note: Pay attention to its direction.

4. Select proper snap ring of 3rd & 4th synchronizer hub to minimize clearance of groove, and then install it.

Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in)
Snap ring of 3rd & 4th synchronizer hub: [1][2]Mechanical Specifications




5. Install 4th input gear.
6. Select proper thrust washers to minimize clearance of groove.
Then install them and thrust washer ring.

Allowable clearance of groove: 0 - 0.06 mm (0 - 0.0024 in)
Input shaft thrust washer: [1][2]Mechanical Specifications




7. Install 5th & reverse synchronizer assembly.
a. Hook insert springs on reverse baulk ring.




b. Install insert springs with reverse baulk ring onto coupling sleeve.

Note: Pay attention to position of insert springs.

c. Place 5th baulk ring on 5th input gear.
d. Install reverse synchronizer cone on reverse baulk ring.




e. Place reverse synchronizer assembly on 5th input gear.
- Mesh recesses of 5th input gear with projections of reverse synchronizer cone.
- Put insert spring mounts on reverse baulk ring upon those on 5th baulk ring.




f. Press on 5th & reverse synchronizer assembly with 5th input gear.







8. Install input shaft front and rear bearings.
9. Measure gear end play as the final check.

ASSEMBLY







1. Place inserts in three grooves on coupling sleeve (1st & 2nd synchronizer).




2. Install 1st main gear and 1st baulk ring.
3. Press on 1st & 2nd synchronizer hub.

Note: Pay attention to its direction.







4. Install coupling sleeve with three inserts and 2nd baulk ring.
5. Select proper snap ring of 1st & 2nd synchronizer hub to minimize clearance of groove and then install it.
Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in)
Snap ring of 1st & 2nd Synchronizer hub: [1][2]Mechanical Specifications




6. Install 2nd main gear.
7. Press on 3rd main gear.




8. Press on 4th main gear.




9. Press on 5th main gear.
10. Select proper snap ring of 5th main gear to minimize clearance of groove and then install it.
Allowable clearance of groove: 0 - 0.15 mm (0 - 0.0059 in)
Snap ring of 5th main gear: [1][2]Mechanical Specifications




11. Press on thrust washer and press on mainshaft rear bearing.




12. Press on mainshaft front bearing.
13. Measure gear end play as the final check.