Part 1
ASSEMBLYGear Components
1. Install 5th/6th coupling sleeve and 5th/6th shifting inserts onto 5th/6th synchronizer hub.
CAUTION:
^ Do not reuse 5th/6th synchronizer hub and 5th/6th coupling sleeve.
^ Install 5th/6th coupling sleeve with the larger chamfer on the rear side.
CAUTION: Be careful with the shape of shifting insert to avoid misassembly.
2. Install 5th/6th spread springs in 5th/6th shifting inserts.
CAUTION: Install the hook of each spread spring onto separate shifting inserts.
3. Install 6th needle bearing, 6th main gear, 6th baulk ring and 5th 6th synchronizer assembly onto main shaft using a press and the inserter.
Tool number : ST30911000 ( - )
CAUTION: The rear side of synchronizer hub has three oil grooves. When press fitting, install the rear side to the rearward.
4. Select and install snap ring onto the front side of main shaft so that the end play comes within the specifications. Refer to Snap Rings.
End play: 0 - 0.1 mm (0 - 0.004 inch)
CAUTION: Do not reuse snap ring.
5. Install 1st/2nd coupling sleeve and 1st/2nd shifting inserts onto 1st/2nd synchronizer hub.
CAUTION:
^ Do not reuse 1st/2nd synchronizer hub and 1st/2nd coupling sleeve.
^ Install 1st/2nd coupling sleeve with the thicker flange faced the front side.
CAUTION: Be careful with the shape of shifting insert to avoid misassembly.
6. Install 1st/2nd spread spring in 1st/2nd shifting inserts onto 1st/2nd synchronizer hub.
CAUTION: Install hook of each spread spring onto separate shifting inserts.
7. Install 2nd needle bearing, 2nd main gear, 2nd inner baulk ring, 2nd synchronizer cone, 2nd outer baulk ring and 1st/2nd synchronizer assembly onto main shaft using a press and the support ring.
Tool number : ST27861000 ( - )
CAUTION: Install with the side, which has identification mark on one of four oil grooves on the boss edge surface, facing rearward.
8. Install 1st gear bushing onto main shaft using a press and the support ring.
Tool number : ST27861000 ( - )
9. Install 1st needle bearing, 1st outer baulk ring, 1st synchronizer cone, 1st inner baulk ring, 3rd main gear and 1st main gear onto main shaft using a press and the inserter.
Tool number : ST30022000 ( - )
CAUTION: Do not reuse 3rd main gear.
10. Install 3rd/4th main spacer and 4th main gear onto main shaft using a press and the inserter.
Tool number : ST30022000 ( - )
CAUTION:
^ Do not reuse 4th main gear.
^ Install with the side on which the boss protrudes out of gear edge surface facing rearward.
11. Install main shaft bearing onto main shaft using a press and the inserter.
Tool number : ST30911000 ( - )
12. Install reverse main gear bushing onto main shaft using a press and the inserter.
Tool number : ST30911000 ( - )
13. Install 3rd gear bushing onto counter shaft using a press and the inserter.
Tool number : ST30911000 ( - )
14. Install 3rd/4th coupling sleeve and 3rd/4th shifting inserts onto 3rd/4th synchronizer hub.
CAUTION:
^ Do not reuse 3rd/4th synchronizer hub and 3rd/4th coupling sleeve.
^ Install 3rd/4th coupling sleeve with the thicker flange faced the front side.
CAUTION: Be careful with the shape of shifting insert to avoid misassembly.
15. Install 3rd/4th spread springs into 3rd/4th shifting insert.
CAUTION: Install the hook of each spread spring onto separate shifting inserts.
16. Install 3rd needle bearing, 3rd counter gear, 3rd inner baulk ring, 3rd synchronizer cone, 3rd outer baulk ring and 3rd/4th synchronizer assembly onto counter shaft using a press and the drift.
Tool number : ST30911000 ( - )
17. Install 4th outer baulk ring, 4th synchronizer cone, 4th inner baulk ring, 4th gear bushing, 4th needle bearing, 4th counter gear and 4th counter shaft thrust washer onto counter shaft using a press and the drift.
Tool number : KV40100630 (J-26029)
18. Install counter rear bearing inner race onto counter shaft using a press and the drift.
Tool number : ST30032000 (J-26010-01)
19. Install main drive bearing onto main drive gear using a press and the drift.
Tool number : KV32102700 ( - )
20. Select and install snap ring on main drive gear so that comes within the specifications. Refer to Snap Rings.
End play: 0 - 0.1 mm (0 - 0.004 inch)
CAUTION: Do not reuse snap ring.
21. Install 5th baulk ring, pilot bearing spacer, main pilot bearing and main drive gear onto main shaft.
22. Install main shaft and counter shaft combined in one unit to adapter plate, and secure main shaft bearing with a snap ring.
a. Tap main shaft bearing slightly via brass bar or the equivalent to install snap ring.
b. After installing snap ring, hammer snap ring and adapter plate slightly in the reverse direction to make them in contact with each other.
CAUTION: Do not reuse snap ring.
23. Install counter rear bearing outer race onto adapter plate using plastic hammer or equivalent.
24. Apply genuine medium strength locking sealant or equivalent to the end of the bolt (first 3 to 4 threads). Install main shaft bearing retainer onto adapter plate, and tighten bolts to the specified torque. Refer to CASE COMPONENTS.
25. Install reverse coupling sleeve and reverse shifting inserts onto reverse synchronizer hub.
CAUTION:
^ Do not reuse reverse synchronizer hub and reverse coupling sleeve.
^ Install reverse coupling sleeve with the flat flange on the rear side.
CAUTION: Be careful with the shape of shifting insert to avoid misassembly.
26. Install spread springs into shifting insert.
CAUTION: Install the hook of each spread spring onto separate shifting inserts.
27. Install reverse main needle bearing, reverse main gear, reverse baulk ring and reverse synchronizer assembly onto main shaft using a press, the press plate and the drift.
Tool number (A) : KV32103300 (J-46529)
Tool number (B) : ST01530000 ( - )
CAUTION: When installing, face the side with three grooves to the front side.
28. Select and install a snap ring to the main shaft rear side so that the end play comes within the standard value. Refer to Snap Rings.
End play: 0 - 0.1 mm (0 - 0.004 inch)
CAUTION: Do not reuse snap ring.
29. Install counter rear bearing spacer and reverse counter gear using a press and the drift.
Tool number : ST23860000 ( - )
CAUTION:
^ Do not reuse reverse counter gear.
^ When installing counter rear bearing spacer, maker's stamp should face to the rear.
30. Select and install a snap ring to the counter shaft so that the end play comes within the standard value. Refer to Snap Rings.
End play: 0 - 0.1 mm (0 - 0.004 inch)
CAUTION: Do not reuse snap ring.
Shift Control Components
1. Install 5th6th shift fork to 5th/6th coupling sleeve.
2. Install 5th6th fork rod (reversal side) to 5th6th shift fork.
3. Drive retaining pin into 5th6th shift fork using a pin punch [6 mm (0.24 inch) dia.].
CAUTION: Do not reuse retaining pin.
4. Install 5th/6th fork rod to adapter plate.
5. Install 5th/6th fork rod bracket to 5th/6th fork rod.
6. Drive retaining pin into 5th/6th fork rod bracket using a pin punch [6 mm (0.24 inch) dia.].
CAUTION: Do not reuse retaining pin.
7. Install 5th/6th control lever to adapter plate, and then tighten mounting bolts to the specified torque. Refer to SHIFT CONTROL COMPONENTS.
CAUTION: Set the projection upward.
8. Insert check balls into adapter plate.
9. Install reverse shift fork onto reverse coupling sleeve.
10. Insert reverse fork rod to reverse shift fork.
11. Drive retaining pin into reverse shift fork using a pin punch [6 mm (0.24 inch) dia.].
CAUTION: Do not reuse retaining pin.
12. Insert interlock pin and interlock plunger into adapter plate.
13. Install 1st/2nd shift fork onto 1st/2nd coupling sleeve.
14. Insert 1st/2nd fork rod to 1st/2nd shift fork.