Part 1
ASSEMBLYGear Components
1. Install 5th - 6th coupling sleeve and 5th - 6th shifting insert in the 5th - 6th synchronizer hub.
CAUTION: Install 5th - 6th coupling sleeve with the larger chamfer on the rear side.
2. Install 5th - 6th spread spring in the 5th - 6th shifting insert.
CAUTION:
^ Do not install 5th - 6th spread spring hook onto the same 5th - 6th shifting insert.
^ Be careful with the shape of reserve shifting insert to avoid misassembly.
3. Install 6th needle bearing, 6th main gear and 6th baulk ring on the main shaft and then using an inserter and a press to press fit the 5th - 6th synchronizer assembly.
Tool number: ST30911000 (-)
CAUTION:
^ The 5th - 6th synchronizer hub is not reusable. Never reuse it.
^ When press fitting, install with the side having the three boss edge oil grooves facing the rear side.
NOTE: 5th and 6th baulk rings have three spaces that two gear teeth are missing as shown in the figure.
4. Select and install a snap ring so that the end play comes within the standard value.
End play: 0 - 0.10 mm (0 - 0.004 inch)
CAUTION: Snap rings are not reusable. Never reuse them.
5. Install 1st - 2nd coupling sleeve and 1st - 2nd shifting insert into the 1st - 2nd synchronizer hub.
CAUTION: Install 1st - 2nd coupling sleeve with the thicker flange faced the front side.
6. Install 1st - 2nd spread spring in the 1st - 2nd shifting insert.
CAUTION:
^ Do not install 1st - 2nd spread spring hook onto the same 1st - 2nd shifting insert.
^ Be careful with the shape of reverse shifting insert to avoid misassembly.
7. Install 2nd main gear, 2nd needle bearing, 2nd inner baulk ring, 2nd synchronizer cone, 2nd outer baulk ring on the main shaft and then using a support ring and a press to press fit the 1st - 2nd synchronizer assembly.
Tool number: ST27861000 (-)
CAUTION:
^ The 1st - 2nd synchronizer hub is not reusable. Never reuse it.
^ When press fitting, install with the side having the three boss edge oil grooves facing the front side.
NOTE: 1st baulk ring has three spaces that one gear tooth is missing and 2nd baulk ring has three spaces that two gear teeth are missing.
8. Using a support ring and a press to press fit the 1st gear bushing.
Tool number: ST27861000 (-)
9. Install 1st outer baulk ring, 1st synchronizer cone, 1st inner baulk ring, 1st needle bearing, and 1st main gear on the main shaft and then using the inserter and a press to press fit the 3rd main gear.
Tool number: ST30022000 (-)
CAUTION: 3rd main gear is not reusable. Never reuse it.
10. Install 3rd - 4th main spacer on the main shaft and then using the inserter and a press to press fit the 4th main gear.
Tool number: ST30022000 (-)
CAUTION:
^ 4th main gear is not reusable. Never reuse it.
^ When installing, set boss to rear side.
11. Using the inserter and a press to press fit the main shaft bearing onto the main shaft.
Tool number: ST30911000 (-)
12. Using the inserter and a press to press fit the reverse main gear bushing onto the main shaft.
Tool number: ST30911000 (-)
13. Using the inserter and a press to press fit the 3rd gear bushing onto the counter shaft.
Tool number: ST30911000 (-)
14. Install 3rd - 4th coupling sleeve and 3rd - 4th shifting insert into the 3rd - 4th synchronizer hub.
CAUTION: Install 3rd - 4th coupling sleeve with the thicker flange faced the front side.
15. Install 3rd - 4th spread spring in the 3rd - 4th shifting insert.
CAUTION:
^ Do not install 3rd - 4th spread spring hook onto the same 3rd - 4th shifting insert.
^ Be careful with the shape of reverse shifting insert to avoid misassembly.
16. Install 3rd needle bearing, 3rd counter gear, 3rd inner baulk ring, 3rd synchronizer cone, and 3rd outer baulk ring on the counter shaft and then using the inserter and a press to press fit the 3rd - 4th synchronizer assembly.
Tool number: ST30911000 (-)
CAUTION:
^ The 3rd - 4th synchronizer hub is not reusable. Never reuse it.
NOTE: 4th baulk ring has three spaces that one gear tooth is missing but 3rd baulk ring doesn't.
17. Install 4th outer baulk ring, 4th synchronizer cone, 4th inner baulk ring, 4th needle bearing, and 4th counter gear onto the counter shaft and then using the inserter and a press to press fit the 4th gear bushing and 4th counter gear thrust washer.
Tool number: KV40100630 (J26092)
18. Using the inserter and a press to press fit the counter rear bearing inner race onto the counter shaft.
Tool number: ST30032000 (J26010-01)
19. Using the drift and a press to press fit the main drive gear bearing onto the main drive gear.
Tool number: KV32102700 (-)
20. Select and install a snap ring to the main drive gear bearing so that the end play comes within the standard value.
End play: 0 - 0.10 mm (0 - 0.004 inch)
CAUTION: Snap rings are not reusable. Never reuse them.
21. Install main shaft and counter shaft combined in one unit to adapter plate, and fix bearing with snap ring.
CAUTION: Snap rings are not reusable. Never reuse them.
22. Install counter rear bearing onto the adapter plate using soft hammer or the equivalent.
23. Apply genuine medium strength locking sealant or equivalent to the end of the bolt (first 3 to 4 threads), screw the bolt into the main shaft bearing retainer, and tighten it to the specified torque.
24. Install reverse coupling sleeve and reverse shifting insert into the reverse synchronizer hub.
CAUTION: Install reverse coupling sleeve with the flat flange on the rear side.
25. Install reverse spread spring in the reverse shifting insert.
CAUTION: Do not install reverse spread spring hook onto the same reverse shifting insert.
26. After installing reverse main gear bushing, reverse main needle bearing, reverse main gear, and reverse baulk ring onto the main shaft, using the drift and press plate and a press to press fit the reverse synchronizer assembly.
Tool number (A): KV32103300 (J46529)
Tool number (B): ST01530000 (-)
CAUTION:
^ The reverse synchronizer hub is not reusable. Never reuse it.
^ When installing, face the side with three ditches to the front side.
27. Install reverse coupling snap ring.
NOTE: Reverse baulk ring has three spaces that two gear teeth are missing, and each space has small ditch for identification as shown in the figure.
28. Select and install a snap ring so that the end play comes within the standard value.
End play: 0 - 0.10 mm (0 - 0.004 inch)
CAUTION: Snap rings are not reusable. Never reuse them.
29. After installing counter rear bearing spacer, press and fit reverse counter gear onto counter shaft with drift and press.
Tool number: ST23860000 (-)
CAUTION:
^ Reverse counter gear is not reusable. Never reuse it.
^ When installing counter rear bearing spacer, maker's stamp should face to the rear
30. Select and install a snap ring so that the end play comes within the standard value.
End play: 0 - 0.10 mm (0 - 0.004 inch)
CAUTION: Snap rings are not reusable. Never reuse them.
Shift Control Components
1. Install 5th - 6th shift fork to the 5th - 6th coupling sleeve.
2. Install 5th - 6th fork rod (reversal side) to the 5th - 6th shift fork.
3. Using a pin punch [6 mm (0.24inch) dia.] to tap the retaining pin into the 5th - 6th shift fork.
CAUTION: Retaining pins are not reusable. Never reuse them.
4. Install 5th - 6th fork rod to the adapter plate.
5. Install 5th - 6th fork rod bracket to the 5th - 6th fork rod.
6. Using a pin punch [6 mm (0.24 inch) dia.] to tap the retaining pin into the 5th - 6th fork rod bracket.
CAUTION: Retaining pins are not reusable. Never reuse them.
7. Install 5th - 6th control lever to the adapter plate and then tighten mounting bolts to the specified torque.
CAUTION: Set the projection upward.