Gear Components - Assembly

GEAR COMPONENTS - Assembly




1. Install bearings into case components.




2. 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.

Allowable clearance of groove:

0 - 0.1 mm (0 - 0.004 in)

Main drive gear snap ring
Refer to S.D.S.

d. Install selected snap ring on main drive gear.




3. Install components on counter gear.

a. Install sub-gear components.

When Installing sub-gear snap ring, tap sub-gear snap ring into position on counter gear.




b. Install counter gear rear thrust bearing.




4. Install front side components on mainshaft.

a. Assemble 1st & 2nd synchronizer.




b. Assemble 3rd & 4th synchronizer.




c. Press on 3rd & 4th synchronizer assembly together with 3rd main gear and 3rd gear needle bearing.

Pay attention to direction of synchronizer assembly.




d. Select proper snap ring to minimize clearance of groove.

Allowable clearance of groove:

0 - 0.1 mm (0 - 0.004 in)

Mainshaft front snap ring: Refer to S.D.S.
e. Install selected snap ring on mainshaft.




When Installing counter gear Into counter gear rear bearing, push up on upper roller of counter gear rear bearing with screwdriver.




d. Install Tools (J26349-3) onto adapter plate and C-ring and C-ring holder on mainshaft.

e. Install Tool (J34328) on mainshaft.




f. Install mainshaft and counter gear completely by extending length of J-34328-2 threaded legs.




8. Install rear side components on mainshaft and counter gear.

a. Install O.D. gear bushing while pushing on the front of counter gear.

b. Install O.D. main gear.




Pay attention to direction of O.D. main gear. (B is wider than A as shown.)

c. Install adapter plate with gear assembly onto transmission case.

d. Install O.D. gear needle bearing and then install O.D. counter gear and reverse idler shaft.




e. Install reverse gear bushing, speedometer, drive gear and steel ball.




f. Install reverse cone.




g. Install insert springs and reverse baulk ring on O.D. coupling sleeve. Then install them and O.D. baulk ring on O.D. counter gear.

Pay attention to direction of O.D. coupling sleeve.







h. Install reverse counter gear.




i. Install sub-gear on reverse idler gear.

j. Install reverse gear needle bearing and then install reverse main gear, reverse idler gear and reverse idler thrust washers.




k. Install reverse hub.
Pay attention to its direction.




l. Install mainshaft spacer and mainshaft rear bearing.




m. Install counter gear rear end bearing.

n. Separate adapter plate from transmission case and Mount adapter plate on vise again.




o. Select proper mainshaft C-ring to minimize clearance of groove.

Allowable clearance of groove:

0 - 0.1 mm (0 - 0.004 in)

Mainshaft C-ring:
Refer to S.D.S.

p. Install selected C-ring, C-ring holder and mainshaft rear snap ring.




q. Install spacer and then select proper counter gear rear snap ring to minimize clearance of groove.

Allowable clearance of groove:

0 - 0.1 mm (0 - 0.004 in)

Counter gear rear snap ring: Refer to S.D.S.

r. Install selected counter gear rear snap ring.




s. Install reverse coupling sleeve.

Pay attention to its direction.

t. Measure each gear end play as a final check - Refer to "DISASSEMBLY".