Assembly

NOTE:
- Before installation, wash each part and apply specified gear oil to sliding faces of bearing and gear.
- Use new circlips on shaft for reinstallation. Don't reuse used circlips.





1. Fit sleeve (2) to low speed hub (1), place 3 synchronizer keys (3) in it and set synchronizer spring (4). Refer to figure for proper installing direction of hub, sleeve and springs. Synchronizer key has no specific direction for installation.

NOTE: When installing each synchronizer spring, insert its hooked end to hub hole and put it toward right.





2. Install needle bearing (1), 2nd gear (2) and 2nd synchronizer ring to main shaft (3).





3. Using Special Tool (A) 09927-08210, press-fit sleeve and hub assembly (1) onto main shaft (2) with press.





4. Insert low gear bush (1) and set synchronizer ring (2) needle bearing (3) and low gear (4).





5. Set steel ball (1) and washer (2).





6. Using special tools and press, press-fit bearing (1).
Special Tools:
(B) 09925-18010
(C) 09927-08210
(D) 09940-53111





7. Fit sleeve (1) to reverse hub (2), place 3 synchronizer keys (3) in it and then set synchronizer springs (4). Refer to figure for proper installing direction of hub, sleeve and springs. Also, note that key has specific installing direction.





8. Set steel ball and bearing washer (1) and insert reverse gear bush (2), needle bearing (3) and reverse gear (4).





9. Press-fit reverse sleeve and hub assembly (1) with special tools and press.
Special Tools:
(B) 09925-18010
(C) 09927-08210
(D) 09940-53111





10. After setting large circlip (1), install 5th speed synchronizer ring, needle bearing, 5th gear (2), steel ball (3) and washer (4).

NOTE: Washer should be installed with its oil slot side facing gear.





11. Press-fit bearing (1) with Special Tool (B) 09925-18010 and fit small circlip.





12. Fit small circlip (1), using Special Tool (D) 09951-16080, fit speedometer drive gear (2) and then fit the other small circlip.





13. Fit sleeve (1) to high speed hub (2), place 3 synchronizer keys (3) and set synchronizer springs (4) as shown. Neither sleeve nor key has specific installing direction.





14. Install needle bearing, 3rd gear (3) and 3rd synchronizer ring (2). Then using Special Tool (E) 09913-84510 and press, press-fit high speed sleeve and hub assembly (1) onto shaft.
15. Fit large circlip.
16. Install needle bearing.