Disassembly and Assembly

Disassembly







1. Before disassembly, check 3rd, 4th and 5th input gear end plays.

Gear end play:Service Data and Specifications (SDS)

Note: If not within specification, disassemble and check contact surface of gear, shaft and hub. Check clearance of snap ring groove. Refer to "ASSEMBLY."




2. Remove input shaft rear bearing with Tool.




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




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




5. Remove snap ring.




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




7. Remove input shaft front bearing with Tool.

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: Service Data and Specifications (SDS)




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: Service Data and Specifications (SDS)




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.

Note: Mesh recesses of 5th input gear with projections of reverse synchronizer cone.

Note: 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.