1. Assemble in the order indicated in the table.
1
|
Counter reverse gear
|
2
|
Thrust washer
|
3
|
Reverse idler gear
|
4
|
Reverse idler gear shaft
|
5
|
Thrust washer
|
6
|
Bearing cover
|
7
|
Thrust washer
|
8
|
Bearing race
|
9
|
Bearing
|
10
|
Reverse gear
|
11
|
Reverse synchronizer ring
|
12
|
5th/reverse clutch hub component
|
13
|
Locknut
|
14
|
Synchronizer ring (5th)
|
15
|
Retaining ring
|
16
|
5th gear
(See 5th Gear Assembly Note.)
|
17
|
Bearing
|
18
|
Steel ball
|
19
|
Thrust lock washer
|
20
|
C-clip
|
21
|
1st/2nd shift rod
|
22
|
Interlock pin (large)
|
23
|
Interlock pin (small)
|
24
|
3rd/4th shift rod
|
25
|
Interlock pin (large)
|
26
|
5th/reverse shift fork
|
27
|
Spring
|
28
|
5th/reverse shift rod
|
29
|
Retaining ring
|
30
|
Spring cap, spring, detent ball
|
31
|
Spring cap, spring, spring seat, detent ball
|
32
|
Blind cover
|
33
|
Center housing
(See Center Housing Assembly Note.)
|
34
|
Set bolt, packing
|
35
|
Oil passage
|
36
|
Spacer
|
37
|
Counter 5th gear
|
38
|
Countershaft rear bearing
|
39
|
Locknut
|
40
|
Mainshaft rear bearing
|
41
|
C-clip
|
42
|
Bearing housing
|
43
|
Pin and retaining ring
|
44
|
Spring
|
45
|
Spring retainer
|
46
|
Retaining ring
|
47
|
1st/2nd shift rod end
(See Shift Rod End Assembly Note.)
|
48
|
3rd/4th shift rod end
(See Shift Rod End Assembly Note.)
|
49
|
5th/reverse shift rod end
(See Shift Rod End Assembly Note.)
|
50
|
Oil passage
|
1. Identify the 5th and reverse synchronizer rings according to the identification marks and assemble.
1. Shift the clutch hub sleeves to engage the 1st and 4th gears.
2. Install a new locknut using the SST.
3. Measure clearance A between the synchronizer key and synchronizer ring.
4. Stake the locknut into the mainshaft groove.
1. Assemble a new retaining ring.
2. Install the synchronizer ring, 5th gear and bearing.
3. Install the steel ball and thrust lock washer.
4. Install the 3.0 mm {0.118 in} C-clip.
5. Measure the clearance (5th gear end play) between the thrust lock washer and C-clip.
|
Thickness (mm {in})
|
---|---|
Thrust lock washer |
6.2 {0.244}
|
6.3 {0.248}
|
|
6.4 {0.252}
|
|
6.5 {0.256}
|
|
6.6 {0.260}
|
|
6.7 {0.264}
|
1. Slide the 1st/2nd shift rod.
2. Assemble a new roll pin in the direction shown in the figure.
3. Slide the SSTs into the transmission case to guide the interlock pins, and insert the first pin.
4. Remove the SST (for 3rd/4th shift fork guide) from the transmission case.
5. Slide the 3rd/4th shift rod containing the interlock pin (small) into the transmission case.
6. Secure the 3rd/4th shift rod onto the fork with the new roll pin.
7. Insert the remaining interlock pin and remove the SSTs.
8. Assemble the 5th/reverse fork to the clutch hub.
9. Assemble the 5th/reverse shift rod in the transmission case through the spring.
10. Install a new retaining ring using the SST.
11. Assemble a new roll pin in the direction as shown in the figure and secure the 5th/reverse shift fork to the shift rod.
12. Assemble the blind covers, wiring harness clip and new gaskets.
13. Install new packing, detent balls, spring seats, springs and spring caps.
1. Apply sealant to the contact surfaces of the transmission case and center housing as shown in the figure.
2. Install the oil passage to the center housing.
3. Install the center housing.
4. Align the reverse idler gear shaft with the set bolt hole, and install the packing and set bolt.
5. Assemble the spacer and counter 5th gear.
1. Assemble the countershaft rear bearing using the SSTs.
2. Install the SST to the mainshaft and secure it in a vise.
3. Shift the 1st/2nd shift rod and 5th/reverse shift rod to engage the 1st gear and reverse gear.
4. Tighten a new locknut.
5. Stake the locknut into the countershaft groove.
1. Assemble the mainshaft rear bearing using the SST.
2. Install the C-clip.
3. Measure the clearance between C-clip and groove.
1. Apply sealant to the contact surfaces of the center housing and bearing housing as shown in the figure.
2. Assemble the bearing housing.
1. Assemble the shift rod ends onto the proper shift rods, and secure them with new roll pins pointing in the direction shown in the figure.