MAIN DRIVE GEAR AND MAINSHAFT COMPONENT ASSEMBLY

BHE051117050105

1. Assemble in the order indicated in the table.

2. Verify the following after assembly.

(1) The gear rotates smoothly when rotated by hand.

(2) The synchronizer ring is not stuck.


1	Main drive gear
2	Bearing (See Bearing Assembly Note.)
3	Snap ring (bearing) (See Snap Ring (Bearing) Assembly Note.)
4	Synchronizer ring
5	Needle bearing
6	Clutch hub
7	Synchronizer key
8	Synchronizer key spring
9	Steel ball
10	Clutch hub sleeve
11	Mainshaft
12	Needle bearing
13	Reverse gear
14	Synchronizer ring
15	Clutch hub component (5th/reverse) (See Clutch Hub Component (5th/reverse) Assembly Note.)
16	Snap ring (reverse gear) (See Snap Ring (Reverse Gear) Assembly Note.)
17	Needle bearing
18	2rd gear
19	Inner ring
20	Middle ring
21	Synchronizer ring
22	Clutch hub component (1st/2nd) (See Clutch Hub Component (1st/2nd) Assembly Note.)
23	Steel ball
24	Synchronizer ring
25	Middle ring
26	Inner ring
27	1st gear
28	Needle bearing
29	Inner race
30	Bearing
31	6th gear (See 6th Gear Assembly Note.)
32	Snap ring (6th gear) (See Snap Ring (6th Gear) Assembly Note.)
33	Main drive gear component

Bearing Assembly Note

1. Install the bearing using the SSTs.

Snap Ring (Bearing) Assembly Note

1. Install the snap ring removed during disassembly, and measure the clearance between the snap ring and the installation groove using a feeler gauge.

2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the main drive gear.

Clearance

0-0.1 mm {0-0.0039 in}

Snap Ring size

mm {in}


Identification mark	Thickness	Identification mark	Thickness
0	1.95 {0.077}	3	2.10 {0.083}
1	2.00 {0.079}	4	2.15 {0.085}
2	2.05 {0.081}	5	2.20 {0.087}

Clutch Hub Component (5th/reverse) Assembly Note

1. Securely align the tab on the synchronizer ring with the key groove of the clutch hub.

Caution

• Do not damage the synchronizer ring when installing the clutch hub component.

2. Carefully install the clutch hub component (5th/reverse) using the SSTs and a press.

Snap Ring (Reverse Gear) Assembly Note

1. Install the snap ring removed during disassembly, and measure the clearance between the snap ring and the installation groove using a feeler gauge.

2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the mainshaft.

Clearance

0-0.1 mm {0-0.0039 in}

Snap Ring size

mm {in}


Identification mark	Thickness	Identification mark	Thickness
A	1.80 {0.071}	D	1.95 {0.077}
B	1.85 {0.073}	E	2.00 {0.079}
C	1.90 {0.075}	F	2.05 {0.081}

Clutch Hub Component (1st/2nd) Assembly Note

1. Securely align the tab on each ring with the installation hole of the 2nd gear and the key groove of the clutch hub.

Caution

• Do not damage each synchronizer ring when installing the clutch hub component.

2. Carefully install the clutch hub component (1st/2nd) using the SSTs and a press.

6th Gear Assembly Note

1. Install the bearing and 6th gear using the SSTs and a press.

Snap Ring (6th Gear) Assembly Note

1. Install the snap ring removed during disassembly, and measure the clearance between the snap ring and the installation groove using a feeler gauge.

2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the mainshaft.

Clearance

0-0.11 mm {0-0.0043 in}

Snap Ring size

mm {in}


Identification mark	Thickness	Identification mark	Thickness
A	2.67 {0.105}	G	3.03 {0.119}
B	2.73 {0.107}	H	3.09 {0.122}
C	2.79 {0.110}	J	3.15 {0.124}
D	2.85 {0.122}	K	3.21 {0.126}
E	2.91 {0.115}	L	3.27 {0.129}
F	2.97 {0.117}	-	-