Assembly

Gear Components: Assembly

1) Install mainshaft front bearing snap ring to mainshaft front bearing.
2) Install bearings into case components using Tools.










3) Install bearing retainer. Tighten bearing retainer bolts to the specified torque.
[Service Data and Specifications] Transmission Disassembly and Assembly





4) Install main drive gear bearing.





a) Press main drive gear bearing using Tool.






b) Select proper main drive gear snap ring to minimize clearance of groove. Refer to Mechanical Specifications.





[Service Data and Specifications] Mechanical Specifications





CAUTION:
Do not reuse main drive gear snap ring.

c) Install selected new main drive gear snap ring on main drive gear.
5) Install front side components on mainshaft.





a) Assemble 1st and 2nd synchronizer.

CAUTION:
Do not reuse 1st and 2nd synchronizer hub.

b) Assemble 3rd and 4th synchronizer.






CAUTION:
Do not reuse 3rd and 4th synchronizer hub.

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






CAUTION:
Pay attention to direction of synchronizer assembly.

d) Select proper mainshaft front snap ring to minimize clearance of groove. Refer to Mechanical Specifications.











CAUTION:
Do not reuse mainshaft front snap ring.

e) Install selected new mainshaft front snap ring on mainshaft.
f) Press on 1st and 2nd synchronizer assembly together with 2nd main gear and 2nd gear needle bearing.






CAUTION:
Pay attention to direction of synchronizer assembly.

g) Press on 1st gear bushing using 1st gear washer.





h) Install 1st main gear and 1st gear needle bearing.
i) Install steel ball and 1st gear washer.






CAUTION:
Apply multi-purpose grease to steel ball and 1st gear washer before installing.

6) Install components on counter gear.
a) Install steel ball, sub-gear bracket and new sub-gear snap ring.

CAUTION:
- Apply multi-purpose grease to steel ball.
- Do not reuse sub-gear snap ring.

b) Install counter gear rear thrust bearing using a brass drift.






CAUTION:
Be careful not to damage counter gear rear thrust bearing.

7) Select proper counter gear front bearing shim when replacing transmission case, counter gear, counter gear rear thrust bearing or sub-gear bracket.





a) Install counter gear, counter gear front thrust bearing and counter gear rear thrust bearing on adapter plate.
b) Place adapter plate and counter gear assembly in transmission case (case inverted).
c) Tighten adapter plate to transmission case using 2 bolts.





d) Place dial indicator on rear end of counter gear.
e) Move counter gear up and down and measure dial indicator deflection.
f) Select proper counter gear front bearing shim using the table as a guide. Refer to [Service Data and Specifications] Mechanical Specifications.






g) Separate adapter plate and transmission case.
h) Remove counter gear assembly.
8) Select proper reverse idler thrust washer when replacing rear extension, reverse idler gear or reverse idler shaft.





a) Install reverse idler thrust washer, reverse idler gear, reverse idler needle bearings and reverse idler shaft into rear extension.
- When replacing reverse idler thrust washer, install either (A or B). Refer to [Service Data and Specifications] Mechanical Specifications.
b) Place dial indicator on front end of reverse idler shaft.





c) Put straightedge on front surface of rear extension as a stopper of reverse idler shaft.
d) Move reverse idler shaft up and down and measure end play.
[Service Data and Specifications] Mechanical Specifications





e) If not within specification, replace reverse idler thrust washer with the other (A or B) and check again.
9) Install mainshaft and counter gear on adapter plate and main drive gear on mainshaft.





a) Mount adapter plate on vise and apply multi-purpose grease to counter gear rear bearing.
b) Partially install mainshaft on mainshaft front bearing using suitable tool.






CAUTION:
To allow for installation of counter gear, do not install mainshaft completely.

c) Install counter gear in counter gear rear bearing and install main drive gear, pilot bearing and spacer on mainshaft.






NOTE:
When installing counter gear into counter gear rear bearing, push up on upper roller of counter gear rear bearing using suitable tool.





d) Install Tool onto adapter plate and mainshaft C-ring and C-ring holder on mainshaft.











e) Install Tool on mainshaft.






f) Install mainshaft and counter gear completely by extending length of Tool.





10) Install rear side components on mainshaft and counter gear.





a) Install new OD gear bushing using Tool while pushing on the front of counter gear.






CAUTION:
Do not reuse OD gear bushing.

b) Install OD main gear using Tool.











CAUTION:
Pay attention to direction of OD main gear. [(B) is wider than (A) as shown].

c) Install adapter plate with gear assembly onto transmission case.
d) Install OD gear needle bearing and then install OD counter gear and reverse idler shaft.
e) Install new reverse gear bushing using Tool.











CAUTION:
Do not reuse reverse gear bushing.

f) Install reverse cone using Tool.











g) Install spring inserts and reverse baulk ring on OD coupling sleeve. Then install them and OD baulk ring on OD counter gear.






CAUTION:
Pay attention to direction of OD coupling sleeve.





h) Install reverse counter gear using Tool.











i) Install reverse gear needle bearings, reverse idler needle bearings and then install reverse main gear, reverse idler gear and selected reverse idler thrust washer.
j) Install new reverse synchronizer hub using Tool.











CAUTION:
- Pay attention to direction of reverse synchronizer hub.
- Do not reuse reverse synchronizer hub.

k) Install mainshaft spacer and mainshaft rear bearing using Tools.






l) Install counter gear rear end bearing using Tool.











m) Separate adapter plate from transmission case and mount adapter plate on vise again.
n) Select proper mainshaft C-ring to minimize clearance of groove. Refer to Mechanical Specifications.





[Service Data and Specifications] Mechanical Specifications





o) Install selected mainshaft C-ring, C-ring holder and new mainshaft rear snap ring using suitable tool.






CAUTION:
Do not reuse mainshaft rear snap ring.

p) Select proper counter gear rear snap ring to minimize clearance of groove. Refer to Mechanical Specifications.





[Service Data and Specifications] Mechanical Specifications





CAUTION:
Do not reuse counter gear rear snap ring.

q) Install selected new counter gear rear snap ring using suitable tool.





r) Install reverse coupling sleeve.






CAUTION:
Pay attention to direction of reverse coupling sleeve.

s) Measure each gear end play as a final check. Refer to Mechanical Specifications.