Countershaft Fifth Gear Synchro Installation

Installing Fifth Gear Thrust Washer Pin:

1. Install thrust washer pin in countershaft.

Installing Fifth Gear Thrust Washer:

2. Install thrust washer on countershaft. Turn washer until pin engages in washer notch. Flat side of washer faces rear and cone side to front as shown.

Countershaft Fifth Gear Bearing Installation:

3. Lubricate and install fifth gear bearing on countershaft.

Installing Synchro Sleeve On Countershaft Sisth Gear Hub:

4. Install synchro sleeve on hub of countershaft fifth gear. Tapered side of sleeve faces front and flat side faces rear.

Installing Fifth Gear Shift Fork Insynchro Sleeve:

5. Install shift fork in synchro sleeve.

Installing Assembled Countershaft Fifth Gear, Shift Fork And Synchro Sleeve:

Installing Fifth Gear Synchro Struts And Springs:

6. Install assembled fifth gear, synchro sleeve and shift fork. Align fork with shift lug rail and align gear with bearings and countershaft. Start components onto shaft and rail. Then tap gear and fork into place with plastic or rawhide mallet.

Fifth Synchro Clutch Gear And Stop Ring Installation:

7. Assemble and install fifth synchro clutch gear and stop ring in fifth gear hub. Make sure both parts are seated in fifth gear hub.

Installing Fifth Synchro Clutch Snap Ring:

8. Install clutch gear snap ring.
9. Align roll pin holes in shift fork with notches in shift lug rail. Then install roll pins from top side of fork. Note that roll pins are one way fit due to small shoulder at one end of each pin.