PRIMARY SHAFT COMPONENTS ASSEMBLY

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1.  Assemble in the order indicated in the table.

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1
3rd/4th clutch hub
(See 3rd/4th Clutch Hub Assembly Note.)
2
Synchronizer key
3
3rd/4th clutch hub sleeve
4
Synchronizer key spring
5
Primary shaft gear
6
Bearing (primary shaft end)
(See Bearing (Primary Shaft End) Assembly Note.)
7
3rd gear
(See 3rd Gear, 3rd Synchronizer Ring, and 3rd/4th Clutch Hub Component Assembly Note.)
8
Inner cone
9
Double cone
10
3rd synchronizer ring
(See 3rd Gear, 3rd Synchronizer Ring, and 3rd/4th Clutch Hub Component Assembly Note.)
11
3rd/4th clutch hub component
(See 3rd Gear, 3rd Synchronizer Ring, and 3rd/4th Clutch Hub Component Assembly Note.)
12
Retaining ring
13
Ball
14
Sleeve
15
4th synchronizer ring
(See 4th Synchronizer Ring, 4th Gear, and Bearing (4th Gear End) Assembly Note.)
16
Double cone
17
Inner cone
18
4th gear
(See 4th Synchronizer Ring, 4th Gear, and Bearing (4th Gear End) Assembly Note.)
19
Bearing (4th gear end)
(See 4th Synchronizer Ring, 4th Gear, and Bearing (4th Gear End) Assembly Note.)


3rd/4th Clutch Hub Assembly Note

1.  Install the synchronizer key springs in the clutch hub with the hooks in the grooves to hold the three synchronizer key in place.

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3rd/4th synchronizer key size
A: 17.0 mm {0.669 in}
B: 4.25 mm {0.167 in}
C: 5.0 mm {0.20 in}

2.  Align the synchronizer ring grooves with the synchronizer key during assembly.


Bearing (Primary Shaft End) Assembly Note

1.  Install the new bearing using the SST.

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3rd Gear, 3rd Synchronizer Ring, and 3rd/4th Clutch Hub Component Assembly Note

1.  Install the 3rd gear, inner cone, double cone, 3rd synchronizer ring, and 3rd/4th clutch hub component using a press.

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4th Synchronizer Ring, 4th Gear, and Bearing (4th Gear End) Assembly Note

1.  Install the 4th synchronizer ring, double cone, inner cone, 4th gear, and a new bearing using the SST.

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2.  Measure the clearance between the 3rd gear and 2nd gear.

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•  If it exceeds the maximum specification, inspect the contact surfaces of the 3rd gear, 2nd gear and 3rd/4th clutch hub. Replace worn and damaged parts.
3rd gear thrust clearance
Standard: 0.05—0.20 mm {0.002—0.007 in}
Maximum: 0.25 mm {0.010 in}

3.  Measure the clearance between the 4th gear and bearing.

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•  If it exceeds the maximum specification, inspect the contact surfaces of the 4th gear, bearing, and 3rd/4th clutch hub. Replace worn and damaged parts.
4th gear thrust clearance
Standard: 0.17—0.37 mm {0.007—0.014 in}
Maximum: 0.42 mm {0.017 in}