5TH/REVERSE GEAR COMPONENT ASSEMBLY

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1.  Assemble in the order indicated in the table.

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1
5th counter gear
2
Steel ball
3
5th gear bearing inner race
(See 5th Gear Bearing Inner Race Assembly Note.)
4
Needle bearing
5
5th gear
6
Synchronizer ring
7
5th/reverse clutch hub
8
Synchronizer key spring
9
Synchronizer key
10
Clutch hub sleeve
11
Detent spring
12
Detent ball
13
5th/reverse shift rod
14
5th/reverse shift fork
15
5th/reverse clutch hub and shift fork component
(See 5th Counter Gear, 5th/Reverse Clutch Hub Component and 5th/Reverse Shift Fork Assembly Note.)
16
Retaining bolt
17
Counter lever shaft component
(See Counter Lever Shaft Assembly Note.)
18
Retaining bolt
19
Counter lever
20
Washer
21
Retaining ring
22
Thrust washer
23
Thrust washer
24
Spacer
25
Needle bearing
26
Reverse gear
(See Reverse Gear Assembly Note.)
27
Friction damper
28
Reverse idler gear shaft
29
Thrust washer
30
Needle bearing
31
Reverse idler gear
32
Thrust washer
33
Retaining ring
34
Reverse idler gear shaft component
(See Reverse Idler Gear Component Assembly Note.)
35
Retaining bolt
36
Spacer
37
Reverse counter gear
38
Mainshaft rear bearing
(See Mainshaft Rear Bearing and Countershaft Rear Bearing Locknut Assembly Note.)
39
Locknut
(See Mainshaft Rear Bearing and Countershaft Rear Bearing Locknut Assembly Note.)
40
Thrust washer
41
Countershaft rear bearing
(See Mainshaft Rear Bearing and Countershaft Rear Bearing Locknut Assembly Note.)
42
Locknut
(See Mainshaft Rear Bearing and Countershaft Rear Bearing Locknut Assembly Note.)


5th Gear Bearing Inner Race Assembly Note

1.  Install the steel ball to the countershaft.

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2.  Align the ball groove position of the 5th gear bearing inner race and assemble it to the countershaft.


5th Counter Gear, 5th/Reverse Clutch Hub Component and 5th/Reverse Shift Fork Assembly Note

1.  Assemble the 5th drive gear and 5th/reverse clutch hub component.

Caution
•  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:
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mm {in}

 

A

B

C
5th/6th
18.0 {0.709}
5.45 {0.215}
6.0 {0.236}

•  Align the clutch hub sleeve alignment mark with the clutch hub synchronizer key installation position and assemble.
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2.  Assemble the 5th counter gear component, 5th/reverse clutch hub component, and 5th/reverse shift fork component as a single unit.

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3.  Install the 5th/reverse shift rod retaining bolt.

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Tightening torque:
21.6—30.4 N·m {2.21—3.09 kgf·m, 16.0—22.4 ft·lbf}

4.  Install the thrust washer.

5.  Measure the clearance between thrust washer and groove of the countershaft.

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•  If not within the specification, adjust by choosing the proper thrust washer.
5th/Reverse clutch hub end play
0—0.05 mm {0.0—0.0019 in}

5th/Reverse clutch hub thrust washer

Thickness (mm {in})
3.00 {0.118}
3.05 {0.120}
3.10 {0.122}
3.15 {0.124}
3.20 {0.126}
3.25 {0.128}
3.30 {0.130}
3.35 {0.132}
3.40 {0.134}


Reverse Gear Assembly Note

1.  Measure the clearance A and B.

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(1)  Calculate and select the spacer thickness.
Formula: C = A - B
C: Dimension between the 5th/Reverse clutch hub and reverse gear
B: Reverse gear height
A: Dimension between the 5th/Reverse clutch hub and spacer
•  Refer to the reverse gear spacer selective chart.

Reverse gear spacer

Dimension C (mm {in})

Thickness (mm {in})
7.60—7.70
{0.300—0.303}
7.35 {0.289}
7.70—7.80
{0.304—0.307}
7.45 {0.293}
7.80—7.90
{0.308—0.311}
7.55 {0.297}
7.90—8.00
{0.312—0.314}
7.65 {0.301}
8.00—8.10
{0.315—0.318}
7.75 {0.305}

Reverse gear end play
0.25—0.35 mm {0.010—0.013 in}

2.  Install the spacer.

3.  Install the reverse gear.


Counter Lever Shaft Assembly Note

1.  Install the counter lever shaft component.

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Caution
•  If the counter lever shaft has been replaced or the locknut is loose, assemble the counter lever shaft with the chamfer side of the shaft pointed straight upward.
•  Apply sealant to the threads of the locknut.
•  If there is an abnormality in the 3rd/4th shift stroke after assembling, loosen the locknut and readjust.
Locknut tightening torque:
37.3—51.9 N·m {3.81—5.29 kgf·m, 27.6—38.2 ft·lbf}


Reverse Idler Gear Component Assembly Note

1.  Using the SSTs, install the friction damper to the reverse idler gear.

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•  Verify the depth of the friction damper installation position.
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2.  Assemble the reverse idler gear component.

3.  Measure the clearance between the retaining ring and thrust washer.

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•  If not within the specification, adjust by choosing the proper retaining ring.
Reverse idler gear end play
0.1—0.2 mm {0.0040—0.0078 in}

Reverse idler gear retaining ring

Thickness (mm {in})
1.5 {0.059}
1.6 {0.063}
1.7 {0.067}
1.8 {0.071}
1.9{0.075}

4.  Install the reverse idler gear component to the transmission case.

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5.  Install the reverse idler gear shaft retaining bolt.

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Tightening torque
78.5—117 N·m {8.01—11.9 kgf·m, 57.9—86.2 ft·lbf}


Mainshaft Rear Bearing and Countershaft Rear Bearing Locknut Assembly Note

1.  Slide the 3rd/4th and 1st/2nd clutch hub sleeves to lock the transmission into 4th and 2nd gears.

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2.  Insert the mainshaft rear bearing into the mainshaft and install the locknut.

3.  Attach the SST to the locknut and tighten the nut to the specified torque.

Caution
•  Attach the SST with the locknut seated in the bearing.
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Tightening torque:
211—269 N·m {21.6—27.4 kgf·m, 156—198 ft·lbf}

4.  Tighten the countershaft locknut in the counterclockwise direction.

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Tightening torque:
127—196 N·m {13.0—19.9 kgf·m, 94—144 ft·lbf}

5.  Using the pin punch, stake the mainshaft rear bearing locknut.

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6.  Using the pin punch, stake the countershaft rear bearing locknut.

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