1ST/2ND GEAR COMPONENT, 3RD/4TH GEAR COMPONENT AND COUNTERSHAFT ASSEMBLY

id051100501800

1.  Assemble in the order indicated in the table.

bms1zm00000174

1	Mainshaft
2	Needle bearing
3	2nd gear (See 2nd Gear, 1st Gear, Countershaft Assembly Note.)
4	Inner cone
5	Double cone
6	Synchronizer ring
7	1st/2nd clutch hub (See 1st/2nd Clutch Hub Component Assembly Note.)
8	Synchronizer key
9	Synchronizer key spring
10	Clutch hub sleeve
11	Synchronizer ring
12	Double cone
13	Inner cone
14	1st gear (See 2nd Gear, 1st Gear, Countershaft Assembly Note.)
15	Needle bearing
16	1st gear bearing inner race
17	Mainshaft center bearing (See 1st/2nd Clutch Hub Component Assembly Note.)
18	Needle bearing
19	3rd gear
20	Inner cone
21	Double cone
22	Synchronizer ring
23	Clutch hub (See 3rd/4th Clutch Hub Component Assembly Note.)
24	Synchronizer key (See 3rd/4th Clutch Hub Component Assembly Note.)
25	Synchronizer key spring (See 3rd/4th Clutch Hub Component Assembly Note.)
26	Clutch hub sleeve (See 3rd/4th Clutch Hub Component Assembly Note.)
27	Synchronizer ring
28	Spacer
29	Retaining ring (See 3rd/4th Clutch Hub Component Assembly Note.)
30	Needle bearing
31	Maindrive gear
32	Maindrive gear shaft bearing (See Maindrive Gear Shaft Bearing Assembly Note.)
33	Scoop ring
34	Needle bearing
35	Countershaft (See 2nd Gear, 1st Gear, Countershaft Assembly Note.)
36	Countershaft center bearing race (See Countershaft Center Bearing Race Assembly Note.)
37	Countershaft front bearing race (See Countershaft Front Bearing Race Assembly Note.)

2nd Gear, 1st Gear, Countershaft Assembly Note

1.  If a type A 2nd gear, 1st gear, or countershaft is newly replaced, replace all of the other parts with new ones (type B). In addition, before assembly, verify that all parts are type B based on the number of teeth.

Item		Type A (Number of teeth)	Type B (Number of teeth)
1st gear		38	39
2nd gear		35	36
Countershaft	Counter 1st gear	15	14
	Counter 2nd gear	24	23

Note

•   If 2nd gear, 1st gear, and the countershaft are replaced with new ones (type B), the 1st and 2nd gear ratios for the transmission are low-geared. Therefore, perform PCM reprogramming after installing the transmission to the vehicle as it is necessary to change the gear ratios preset in the PCM.

1st/2nd Clutch Hub Component Assembly Note

Caution

•  There are two types of 1st/2nd clutch hubs as shown in the figure.

1st/2nd clutch hub type A has no specific assembly direction.

Assemble 1st/2nd clutch hub type B in the direction shown in the figure.

bms1zm00000242

D1: 59 mm {2.3 in}

D2: 57 mm {2.2 in}

•  There are two types of clutch hub sleeves as shown in the figure.

Clutch hub sleeve type A has no specific assembly direction.

Assemble clutch hub sleeve type B in the direction shown in the figure.

bms1zm00000243

•  Be sure to assemble the clutch hub components and synchronizer ring components while aligning the synchronizer ring grooves with the synchronizer keys.

•  The standard synchronizer key dimensions are as follows:

bms1zm00000175

mm {in}

	A	B	C
1st/2nd	17.0 {0.669}	5.9 {0.23}	5.0 {0.20}

•  Be sure to align the synchronizer ring projections with the inner cone notches.

•  Be sure to assemble the gears and the synchronizer ring components while aligning the double cone projections with the gear holes as shown in the figure.

bms1zm00000176

•  Align the clutch hub sleeve alignment mark with the clutch hub synchronizer key installation position and assemble.

bms1zm00000177

Caution

•  When using a press, be careful not to damage the parts.

1.  Using a SSTs and press, assemble the needle bearing, 2nd gear, synchronizer ring component (2nd), 1st/2nd clutch hub component, synchronizer ring component (1st), 1st gear, needle bearing, needle bearing race and mainshaft center bearing to the mainshaft at the same time.

bms1zm00000178

3rd/4th Clutch Hub Component Assembly Note

1.  Assemble the 3rd/4th clutch hub component.

Caution

•  The standard synchronizer key dimensions are as follows:

bms1zm00000175

mm {in}

	A	B	C
3rd/4th	17.0 {0.669}	5.9 {0.23}	5.0 {0.20}

•  Be sure to align the synchronizer ring projections with the inner cone notches.

•  Be sure to assemble the gears and the synchronizer ring components while aligning the double cone projections with the gear holes as shown in the figure.

bms1zm00000176

•  Align the clutch hub sleeve alignment mark with the clutch hub synchronizer key installation position and assemble.

bms1zm00000177

2.  Install the 3rd/4th clutch hub component to the mainshaft.

3.  Install the spacer.

4.  Install the retaining ring.

5.  Measure the clearance between retaining ring and spacer.

bms1zm00000179

•  If not within the specification, adjust by choosing the proper retaining ring.

Maindrive Gear Shaft Bearing Assembly Note

1.  Assemble the maindrive gear shaft bearing using the SSTs.

bms1zm00000180

Countershaft Center Bearing Race Assembly Note

1.  Assemble the countershaft center bearing race using the SSTs.

bms1zm00000181

Countershaft Front Bearing Race Assembly Note

1.  Assemble the countershaft front bearing race using the SSTs.

bms1zm00000182