Gear Components

Gear Components
1. Install 5th-6th coupling sleeve and 5th-6th shifting inserts in the 5th-6th synchronizer hub.

CAUTION:
^ Do not reuse 5th-6th coupling sleeve and 5th-6th synchronizer hub.
^ Replace 5th-6th coupling sleeve and 5th-6th synchronizer hub as a set.





^ Install 5th-6th coupling sleeve with the large chamfer on the rear side.

2. Install 5th-6th spread springs in the 5th-6th shifting inserts.

CAUTION:





^ Do not install 5th-6th spread spring hook onto the same 5th-6th shifting insert.





^ Be careful with the shape of reverse shifting insert to avoid misassembly.





3. Install 6th needle bearing, 6th main gear and 6th baulk ring on the main shaft and then using an inserter and a press to press fit the 5th-6th synchronizer assembly.
Tool number: ST30911000 ( - )





CAUTION: When press fitting, install with the side having the three boss edge oil grooves facing the rear side.





NOTE: 5th and 6th baulk rings have three spaces that four gear teeth are missing as shown in the figure.





4. Select and install a snap ring so that the end play comes within the standard value.
End play: 0 - 0.10 mm (0 - 0.004 inch)

CAUTION: Do not reuse snap ring.

5. Install 1st-2nd coupling sleeve and 1st-2nd shifting inserts into the 1st-2nd synchronizer hub.

CAUTION:
^ Do not reuse 1st-2nd coupling sleeve and 1st-2nd synchronizer hub.
^ Replace 1st-2nd coupling sleeve and 1st-2nd synchronizer hub as a set.





^ Install 1st-2nd coupling sleeve with the thicker flange faced the front side.

6. Install 1st-2nd spread springs in the 1st-2nd shifting inserts.

CAUTION:





^ Do not install 1st-2nd spread spring hook onto the same 1st-2nd shifting insert.





^ Be careful with the shape of reverse shifting insert to avoid misassembly.





7. Install 2nd main gear, 2nd needle bearing, 2nd inner baulk ring, 2nd synchronizer cone and 2nd outer baulk ring on the main shaft and then using a support ring and a press to press fit the 1st-2nd synchronizer assembly.
Tool number: ST27861000 ( - )

CAUTION:
^ Replace 2nd inner baulk ring, 2nd synchronizer cone and 2nd outer baulk ring as a set.





^ When press fitting, install with the side having the three boss edge oil grooves facing the front side.





NOTE: 1st baulk ring has three spaces that four gear tooth is missing and 2nd baulk ring has three spaces that two gear teeth are missing.





8. Using a support ring and a press to press fit the 1st gear bushing.
Tool number: ST27861000 ( - )





9. Install 1st outer baulk ring, 1st synchronizer cone, 1st inner baulk ring, 1st needle bearing and 1st main gear on the main shaft and then using the inserter and a press to press fit the 3rd main gear.
Tool number: ST30022000 ( - )

CAUTION:
^ Do not reuse 3rd main gear.
^ Replace 1st outer baulk ring, 1st synchronizer cone and 1st inner baulk ring as a set.





10. Install 3rd-4th main spacer on the main shaft and then using the inserter and a press to press fit the 4th main gear.
Tool number: ST30022000 ( - )

CAUTION:
^ Do not reuse 4th main gear.
^ When installing, set boss to rear side.





11. Using the inserter and a press to press fit the main shaft bearing onto the main shaft.
Tool number: ST30911000 ( - )





12. Using the inserter and a press to press fit the reverse main gear bushing onto the main shaft.
Tool number: ST30911000 ( - )





13. Using the inserter and a press to press fit the 3rd gear bushing onto the counter shaft.
Tool number: ST30911000 ( - )
14. Install 3rd-4th coupling sleeve and 3rd-4th shifting inserts into the 3rd-4th synchronizer hub.

CAUTION:
^ Do not reuse 3rd-4th coupling sleeve and 3rd-4th synchronizer hub.
^ Replace 3rd-4th coupling sleeve and 3rd-4th synchronizer hub as a set.





^ Install 3rd-4th coupling sleeve with the thicker flange faced the front side.

15. Install 3rd-4th spread springs in the 3rd-4th shifting inserts.

CAUTION:





^ Do not install 3rd-4th spread spring hook onto the same 3rd-4th shifting insert.





^ Be careful with the shape of reverse shifting insert to avoid misassembly.





16. Install 3rd needle bearing,3rd counter gear, 3rd inner baulk ring, 3rd synchronizer cone and 3rd outer baulk ring on the counter shaft and then using the inserter and a press to press fit the 3rd-4th synchronizer assembly.
Tool number: ST30911000 ( - )

CAUTION:
^ Replace 3rd inner baulk ring, 3rd synchronizer cone and outer baulk ring as a set.
^ 3rd-4th synchronizer hub must apply the gear oil on the hole spline press fitting side.





NOTE: 4th baulk ring has three spaces that one gear tooth is missing but 3rd baulk ring doesn't.





17. Install 4th outer baulk ring, 4th synchronizer cone, 4th inner baulk ring, 4th needle bearing and 4th counter gear onto the counter shaft and then using the inserter and a press to press fit the 4th gear bushing and 4th counter gear thrust washer.
Tool number: KV40100630 (J-26092)

CAUTION: Replace 4th outer baulk ring, 4th synchronizer cone and 4th inner baulk ring as a set.





18. Using the inserter and a press to press fit the counter rear bearing inner race onto the counter shaft.
Tool number: ST30032000 (J-26010-01)





19. Using the drift and a press to press fit the main drive gear bearing onto the main drive gear.
Tool number: KV32102700 ( - )





20. Select and install a snap ring to the main drive gear bearing so that the end play comes within the standard value.
End play: 0 - 0.10 mm (0 - 0.004 inch)

CAUTION: Do not reuse snap ring.





21. Install main shaft and counter shaft combined in one unit to adapter plate, and fix bearing with snap ring.

CAUTION: Do not reuse snap ring.





22. Install counter rear bearing onto the adapter plate using soft hammer or the equivalent.





23. Apply recommended thread locking sealant to the end of the bolts (first 3 to 4 threads), screw the bolts into the main shaft bearing retainer, and tighten it to the specified torque. Refer to MT-21, "Case Components".
^ Use Genuine Medium Strength Thread Locking Sealant or the equivalent.
24. Install reverse coupling sleeve and reverse shifting inserts into the reverse synchronizer hub.

CAUTION:
^ Do not reuse reverse coupling sleeve and reverse synchronizer hub.
^ Replace reverse coupling sleeve and reverse synchronizer hub as a set.





^ Install reverse coupling sleeve with the flat flange on the rear side.

25. Install reverse spread springs in the reverse shifting inserts.

CAUTION:





^ Do not install reverse spread spring hook onto the same reverse shifting insert.





^ Be careful with the shape of 1st-2nd, 3rd-4th and 5th-6th shifting insert to avoid misassembly.





26. Install snap ring to reverse synchronizer hub.

CAUTION:
^ Do not reuse snap ring.
^ Do not align the snap ring notch with synchronizer hub groove when assembling.





27. After installing reverse main gear bushing, reverse main needle bearing, reverse main gear and reverse baulk ring onto the main shaft, using the drift and press plate and a press to press fit the reverse synchronizer assembly.
Tool number A: KV32103300 (J-46529)
Tool number B: ST01530000 ( - )





CAUTION: When installing, face the side with three ditches to the front side.





NOTE: Reverse baulk ring has three spaces that two gear teeth are missing, and each space has small ditch for identification as shown in the figure.





28. Select and install a snap ring so that the end play comes within the standard value.
End play: 0 - 0.10 mm (0 - 0.004 inch)

CAUTION: Do not reuse snap ring.





29. After installing counter rear bearing spacer, press and fit reverse counter gear onto counter shaft with drift and press.
Tool number: ST23860000 ( - )

CAUTION:
^ Do not reuse reverse counter gear.
^ When installing counter rear bearing spacer, identification ditch should face to the rear side.





30. Select and install a snap ring so that the end play comes within the standard value.
End play: 0 - 0.10 mm (0 - 0.004 inch)

CAUTION: Do not reuse snap ring.