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}