B: Assembly

B: ASSEMBLY








1) Assemble sleeve and hub assembly for 3rd-4th and, 5th and high-low synchronizing.

NOTE: Position open ends of spring 1200 apart.

2) Install 3rd drive gear, baulk ring, and sleeve and hub assembly for 3rd-4th needle bearing (32 x 36 x 25.7) on transmission main shaft.

NOTE: Align groove in baulk ring with shifting insert.





3) Install 4th needle bearing race � onto transmission main shaft using ST1, ST2 and a press.

ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER





4) Install baulk ring, needle bearing (32 x 30 x 25.7), 4th drive gear and 4th gear thrust washer to transmission main shaft.

NOTE: Face thrust washer in the correct direction.





5) Drive ball bearing (1) onto the rear section of transmission main shaft using ST1, ST2 and a press.

ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER





6) Using the same tools as in step 5) above, install the following parts onto the rear section of transmission main shaft.
- 5th gear thrust washer

NOTE: Face thrust washer in the correct direction.

ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER

-= 5th needle bearing race





7) Install the following parts to the rear section of transmission main shaft.
- Needle bearing (32 x 36 x 25.7)
- 5th drive gear
- Baulk ring
- Sleeve (A) and hub assembly
- Insert stopper plate (B)
- Lock washer (C) (22 x 38 x 2)
- Tighten lock nuts (D) (22 x 13) to the specified torque using ST1 and ST2.

ST1 499987003 SOCKET WRENCH (35)
ST2 498937000 TRANSMISSION HOLDER

NOTE:
- Align groove (E) in baulk ring with shifting insert.
- Be sure to fit pawl (F) of insert stopper plate into 4 mm (0.16 in) dia. hole in the boss section of synchronizer hub.
- Secure lock nuts in two places after tightening.

Tightening torque:
118 ± 6 N.m (12.0 ± 0.6 kg-m, 86.8 ± 4.3 ft-lb)