Part 2

BEARINGS
- Make sure bearings roll freely and are free from noise, crack, pitting or wear.

ASSEMBLY
GEAR COMPONENTS





1. Install bearings into case components.





2. Assemble adapter plate parts.
- 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 inch)





Main drive gear bearing snap ring: Refer to image.





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













- Check coupling sleeve and synchronizer hub orientation.





- 3rd & 4th synchronizer





- OD & reverse 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 inch)





Mainshaft front snap ring: Refer to image.

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.
Then select proper snap ring to minimize clearance of groove in counter gear.

Allowable clearance of groove: 0 - 0.13 mm (0 - 0.0051 inch)





Counter drive gear snap ring: Refer to image.

(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 OD & reverse synchronizer to mainshaft.
- Pay attention to direction of hub.





c. Install OD gear bushing with Tool.
d. Install OD main gear and needle bearing.
e. Install spacer, reverse counter gear and OD counter gear.
- OD main gear and OD 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.





- Refer to the figure to determine the converted torque value.
Reference: Formula to convert torque wrench indication to the true torque value:





If the specified torque is T kg-m (ft-lb), the torque wrench scale indication C is determined using the following formula.





9. Tighten counter gear lock nut.
- Always use new lock nut.





10. Stake mainshaft lock nut and countershaft lock nut with a punch.
11. Measure gear end play.
12. Install snap ring and OD mainshaft bearing, then snap ring.

Allowable clearance: 0 - 0.14 mm (0 - 0.0055 inch)





OD mainshaft snap ring: Refer to image.

SHIFT CONTROL COMPONENTS





1. Install fork rods, interlock plunger, interlock balls and check balls.





a. Install 1st-2nd shift fork, then drive in retaining pin.





b. Install 3rd-4th shift fork, then drive in retaining pin.





c. Install OD-reverse shift fork or reverse shift fork, then drive in retaining pin.

CASE COMPONENTS





1. Install front cover oil seal.
- Apply multi-purpose grease to seal lip of oil seal before installing.





2. Apply sealant to mating surface of transmission case.





3. Install gear assembly with adapter plate on transmission case by lightly tapping with a soft hammer.





4. Install snap ring of main drive bearing.





5. Set 1st & 2nd, 3rd & 4th and 5th & reverse shift forks in neutral position.
6. Install striking rod onto adapter plate while aligning striking lever with shift brackets.





7. Apply sealant to mating surface of adapter plate.
8. Install rear extension while inserting striking arm into striking rod.





9. Install striking arm retaining pin.





10. Select counter front bearing shim.





Counter front bearing shim: Refer to image.

11. Install gasket and front cover.





12. Install return spring plugs, check ball, return springs and select check plunger.
13. Install control housing and gasket.