Gear Components
1. Install bearings into case components.
2. Install main drive gear bearing.
a. Press main drive gear bearing.
b. Install main drive gear spacer.
c. Select proper main drive gear snap ring to minimize clearance of groove.
Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in)
Main drive gear snap ring: [1][2]Mechanical Specifications
d. Install selected snap ring on main drive gear.
3. Install components on counter gear.
a. Install sub-gear components.
Note: When installing sub-gear snap ring, tap sub-gear snap ring into position on counter gear.
b. Install counter gear rear thrust bearing.
4. Install front side components on mainshaft.
a. Assemble 1st & 2nd synchronizer.
b. Assemble 3rd & 4th synchronizer.
c. Press on 3rd & 4th synchronizer assembly together with 3rd main gear and 3rd gear needle bearing.
Note: Pay attention to direction of synchronizer assembly.
d. Select proper snap ring to minimize clearance of groove.
Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in)
Mainshaft front snap ring: [1][2]Mechanical Specifications
e. Install selected snap ring on mainshaft.
f. Press on 1st & 2nd synchronizer assembly together with 2nd main gear and 2nd gear needle bearing.
g. Press on 1st gear bushing using 1st gear washer.
h. Install 1st main gear and needle bearing.
i. Install steel ball and 1st gear washer.
Note: Apply multi-purpose grease to steel ball and 1st gear washer before installing.
5. Select proper counter gear front bearing shim when replacing transmission case, counter gear, counter gear thrust bearing or sub-gear components.
a. Install counter gear with sub-gear components, counter gear front and rear thrust bearing on adapter plate.
b. Remove counter gear front bearing shim from transmission case.
c. Place adapter plate and counter gear assembly in transmission case (case inverted).
d. Tighten adapter plate to transmission case using 2 bolts.
e. Place dial indicator on rear end of counter gear.
f. Move counter gear up and down and measure dial indicator deflection.
g. Select proper shim using table in SDS as a guide.
Counter gear end play: 0.10 - 0.25 mm (0.0039 - 0.0098 in)
Table for selecting proper counter gear front bearing shim: [1][2]Mechanical Specifications
Reverse Idler Rear Thrust Washer:
6. Select proper reverse idler rear thrust washer when replacing rear extension, reverse idler gear, reverse idler shaft or reverse idler thrust washer.
a. Install reverse idler gear, reverse idler needle bearings, reverse idler thrust washers and reverse idler shaft into rear extension.
When replacing reverse idler rear washer, install either A or B.
b. Place dial indicator on front end of reverse idler shaft.
c. Put straightedge on front surface of rear extension as a stopper of reverse idler shaft.
d. Move reverse idler shaft up and down and measure reverse idler gear end play.
Reverse idler gear end play: 0.33 - 0.43 mm (0.0130 - 0.0169 in)
e. If not within specification, replace reverse idler rear thrust washer with the other (A or B) and check again.
7. Install mainshaft and counter gear on adapter plate and main drive gear on mainshaft.
a. Mount adapter plate on vise and apply multi-purpose grease to counter gear rear bearing.
b. Install mainshaft a little on mainshaft front bearing.
Note: To allow for installation of counter gear, do not install mainshaft completely.
c. Install counter gear on counter gear rear bearing and install main drive gear, pilot bearing and spacer on mainshaft.
Note: When installing counter gear into counter gear rear bearing, push up on upper roller of counter gear rear bearing with screwdriver.
d. Install tools (J26349-3) onto adapter plate and C-ring and C-ring holder on mainshaft.
e. Install tool (J34328) on mainshaft.
f. Install mainshaft and counter gear completely by extending length of J26349-3.
8. Install rear side components on mainshaft and counter gear.
a. Install OD gear bushing while pushing on the front of counter gear.
b. Install OD main gear.
Note: Pay attention to direction of OD main gear. (B is wider than A as shown above.)
c. Install adapter plate with gear assembly onto transmission case.
d. Install OD gear needle bearing and then install OD counter gear and reverse idler shaft.
e. Install reverse gear bushing.
f. Install reverse cone.
g. Install insert springs and reverse baulk ring on OD coupling sleeve. Then install them and OD baulk ring on OD counter gear.
Note: Pay attention to direction of OD coupling sleeve.
h. Install reverse counter gear.
i. Install sub-gear on reverse idler gear.
j. Install reverse gear needle bearing and then install reverse main gear, reverse idler gear and reverse idler thrust washers.
k. Install reverse hub.
Note: Pay attention to its direction.
l. Install mainshaft spacer and mainshaft rear bearing.
m. Install speedometer drive gear.
n. Install counter gear rear end bearing.
o. Separate adapter plate from transmission case and mount adapter plate on vise again.
p. Select proper mainshaft C-ring to minimize clearance of groove.
Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in)
Mainshaft C-ring: [1][2]Mechanical Specifications
q. Install selected C-ring, C-ring holder and mainshaft rear snap ring.
r. Install spacer and then select proper counter gear rear snap ring to minimize clearance of groove.
Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in)
Counter gear rear snap ring: [1][2]Mechanical Specifications
s. Install selected counter gear rear snap ring.
t. Install reverse coupling sleeve.
Note: Pay attention to its direction.
Gear End Play:
u. Measure each gear end play as a final check.