#
1ST/2ND GEAR COMPONENT, 5TH/6TH GEAR COMPONENT AND COUNTERSHAFT ASSEMBLY

D5E051117040M01

1. Assemble in the order indicated in the table.

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

## 1st/2nd Clutch Hub Component Assembly Note

  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:
mm {in}

| A | B | C
--- | --- | --- | ---
1st/2nd | 17.0 {0.670} | 4.7 {0.185} | 5.0 {0.197}

  • 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.
  • Align the friction damper projections with the clutch hub grooves. (2nd gear)

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

1. Using a SST 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.

  Caution

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

## 5th/6th Clutch Hub Component Assembly Note

1. Place the thrust washers onto the 6th gear.

  Note

  • Apply petroleum jelly making sure the thrust washer does not deviate.

2. Assemble the 5th/6th clutch hub component.

  Caution

  • The standard synchronizer key dimensions are as follows:
mm {in}

| A | B | C
--- | --- | --- | ---
5th/6th | 17.0 {0.670} | 4.25 {0.167} | 5.0 {0.197}

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

3. Install the 5th/6th clutch hub component to the mainshaft.

4. Install the retaining ring.

5. Measure the clearance between retaining ring and groove of the mainshaft.

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

5th/6th clutch hub end play

  0-0.05 mm {0-0.0019 in}

5th/6th clutch hub retaining ring

Thickness (mm {in})
1.50 {0.0591}
1.55 {0.0610}
1.60 {0.0630}
1.65 {0.0650}
1.70 {0.0669}
1.75 {0.0689}
1.80 {0.0709}
1.85 {0.0728}
1.90 {0.0748}
1.95 {0.0768}

## Maindrive Gear Shaft Bearing Assembly Note

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

## Countershaft Center Bearing Race Assembly Note

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

## Countershaft Front Bearing Race Assembly Note

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