MAINSHAFT AND COUNTER SHAFT COMPONENTS ASSEMBLY


BHE051117040M03

1. Assemble in the order indicated in the table.

1
Mainshaft
2
Bearing
3
2nd gear
4
Inner cone
5
Double cone
6
Synchronizer ring (2nd)
7
Synchronizer ring component (2nd)
8
1st/2nd clutch hub
9
Synchronizer key
10
Clutch hub sleeve
11
Synchronizer key spring
12
1st/2nd clutch hub component
13
3rd gear
14
Bearing
15
Inner cone
16
Double cone
17
Synchronizer ring (3rd)
18
Synchronizer ring component (3rd)
 
19
3rd/4th clutch hub
20
Synchronizer key
21
Clutch hub sleeve
22
Synchronizer key spring
23
3rd/4th clutch hub component
24
Snap ring
25
Synchronizer ring (4th)
26
Inner cone
27
Double cone
28
Synchronizer ring (1st)
29
Synchronizer ring component (1st)
 
30
Bearing race
31
Bearing
32
1st gear
33
Countershaft center bearing race
34
Friction gear
35
Diaphram spring
36
Countershaft front bearing spacer
37
Countershaft

Synchronizer Ring Component Assembly Note

1. Assemble the inner cone, double cone and synchronizer ring as shown in the figure.

Clutch Hub Component (1st/2nd, 3rd/4th) Assembly Note

Caution
• Be sure to assemble the clutch hub components and synchronizer ring components while aligning the synchronizer ring grooves with the synchronizer keys.

• The standard synchronizer key dimensions are as follows:

13B-MSP

mm {in}
 
1
2
3
1st/2nd
17.0 {0.670}
4.7 {0.185}
5.0 {0.197}
3rd/4th
17.0 {0.670}
4.25 {0.167}
5.0 {0.197}

13B-Turbo

mm {in}
 
1
2
3
1st/2nd
18.0 {0.709}
5.45 {0.215}
6.0 {0.236}
3rd/4th
17.0 {0.670}
4.25 {0.167}
5.0 {0.197}

EXCEPT 13B-MSP, 13B-Turbo

mm {in}
 
1
2
3
1st/2nd,
3rd/4th
17.0 {0.670}
4.25 {0.167}
5.0 {0.197}
Caution
• Be sure to install each clutch hub component onto the mainshaft in the proper direction.

Caution
• Be sure to align the synchronizer ring projections with the inner cone notches.
• Be sure to assemble the gears and the synchronizer ring components while aligning the double cone projections with the gear holes as shown in the figure.

1. Using a press, assemble the needle bearing, 2nd gear, synchronizer ring component (2nd), 1st/2nd clutch hub component to the mainshaft.

Caution
• When using a press, be careful not to damage the parts.

2. Set the needle bearing, 3rd gear, synchronizer ring (3rd) and 3rd/4th clutch hub component on the mainshaft, then press them onto the mainshaft using the SST.

3. Install a new snap ring on the front of the mainshaft.

Countershaft Center Bearing Race Assembly Note

1. Assemble the countershaft center bearing race using the SSTs.

Countershaft Front Bearing Spacer Assembly Note

Note
• When replacing the countershaft front bearing, replace the spacer.