MAINSHAFT AND COUNTERSHAFT PARTS ASSEMBLY

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1.  Assemble using the procedure shown in the figure.

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1
Countershaft
2
Countershaft front bearing
(See Countershaft Front Bearing Assembly Note.)
3
Snap ring
4
Main shaft gear component
5
6th synchronizer ring
6
Bearing
7
Main drive gear
8
Bearing housing component
(See Bearing Housing Component Assembly Note.)
9
Counter 4th gear
(See Counter 4th Gear Assembly Note.)
10
Washer
11
Gear sleeve
12
Friction damper
13
4th gear
14
4th synchronizer component
(See 4th Synchronizer Component, 3rd Synchronizer Component Assembly Note.)
15
3rd/4th clutch hub
(See 3rd/4th Clutch Hub, 3rd/4th Clutch Hub Sleeve Assembly Note.)
16
Synchronizer key
17
3rd/4th clutch hub sleeve
(See 3rd/4th Clutch Hub, 3rd/4th Clutch Hub Sleeve Assembly Note.)
18
Synchronizer key spring
19
3rd/4th clutch hub component
(See 3rd/4th Clutch Hub Component Assembly Note.)
20
Locknut (main shaft)
(See Locknut (Main Shaft) Assembly Note.)
21
3rd synchronizer component
(See 4th Synchronizer Component, 3rd Synchronizer Component Assembly Note.)
22
3rd gear
23
Steel ball
24
Washer
(See Washer Assembly Note.)
25
Snap ring
26
Spacer
27
Counter 3rd gear
28
Countershaft rear bearing
(See Countershaft Rear Bearing Assembly Note.)
29
Counter reverse gear
30
Locknut (countershaft)
(See Locknut (Countershaft) Assembly Note.)
31
Main shaft rear bearing
(See Main Shaft Rear Bearing Assembly Note.)


Countershaft Front Bearing Assembly Note

1.  Assemble the countershaft front bearing using the SST and the press.

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Bearing Housing Component Assembly Note

1.  Assemble the 6th synchronizer ring, bearing, and main drive gear to the main shaft gear component and secure them using a rope.

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2.  Set the bearing housing component, main shaft gear component, and countershaft to the press.

3.  While gradually pressing the main shaft using a press, lightly tap the countershaft using a plastic hammer to install the main shaft and the countershaft to the bearing housing component.

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Caution
•  Remove the rope before the 1st gear contacts the bearing housing.
•  Assemble the main shaft and the countershaft to the bearing housing component while being careful not to allow the gear of the main shaft to contact the gear of the countershaft.

4.  Assemble the main shaft completely, and then press the countershaft using a press to assemble the countershaft completely.

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Counter 4th Gear Assembly Note

1.  Assemble the counter 4th gear using the SST and a hammer.

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4th Synchronizer Component, 3rd Synchronizer Component Assembly Note

1.  Align the projections of each synchronizer cone with the positions of the gear and clutch hub grooves as shown in the figure and assemble.

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3rd/4th Clutch Hub, 3rd/4th Clutch Hub Sleeve Assembly Note

1.  Assemble so that the surface with the 3rd/4th clutch hub groove is facing the transmission case side.

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2.  Assemble so that the surface with the 3rd/4th clutch hub sleeve marking is facing the extension housing side.


3rd/4th Clutch Hub Component Assembly Note

1.  Assemble the 3rd/4th clutch hub component using the SST and the press.

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Note
•  Use the SST with the larger inner diameter facing the 3rd/4th clutch hub component side.


Locknut (Main Shaft) Assembly Note

1.  Install the SST to the main shaft and secure it to the vise.

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2.  Operate the clutch hub sleeves to engage them with the 5th gear and 2nd gear, and lock the rotation of the main shaft.

3.  Tighten a new locknut (main shaft) using the SST.

Tightening torque
157—235 N·m {17—23 kgf·m, 116—173 ft·lbf}
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4.  Crimp the locknut (main shaft).

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Washer Assembly Note

1.  Assemble the washer which was removed during disassembly and a new snap ring.

Note
•  Assemble the washer so that the side with its groove is facing the 3rd gear.

2.  Using a thickness gauge, measure the clearance between the snap ring and the washer.

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Clearance between snap ring and washer
Standard: 0.1—0.3 mm {0.004—0.011 in}
•  If not within the standard, adjust the clearance by choosing the washer.

Washer thickness (mm {in})
6.2 {0.244}
6.3 {0.248}
6.4 {0.252}
6.5 {0.256}
6.6 {0.260}
6.7 {0.264}


Countershaft Rear Bearing Assembly Note

1.  Assemble the countershaft rear bearing using the SST and the press.

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Note
•  Use the SST with the side which has no height difference facing the countershaft rear bearing side.


Locknut (Countershaft) Assembly Note

1.  Install the SST (49 S120 440) to the main shaft and secure it to the vise.

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2.  Operate the clutch hub sleeves to engage them with the 5th gear and 1st gear, and lock the rotation of the countershaft.

3.  Tighten a new locknut (countershaft).

Tightening torque
127—186 N·m {13—18 kgf·m, 94—137 ft·lbf}

4.  Crimp the locknut (countershaft).

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Main Shaft Rear Bearing Assembly Note

1.  Assemble the main shaft rear bearing using the SST.

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