PROCEDURE
INSTALL FRONT OUTPUT SHAFT BEARING
Using SST and a press, install a new front output shaft bearing to the output shaft.
INSTALL 1ST GEAR BUSHING
Coat the 1st gear bushing with gear oil and install it to the output shaft.
INSTALL 1ST GEAR NEEDLE ROLLER BEARING
Coat the 1st gear needle roller bearing with gear oil and install it to the output shaft.
INSTALL 1ST GEAR
Coat the 1st gear with gear oil and install it to the output shaft.
Install the 1st gear as shown in the illustration.
INSTALL NO. 1 SYNCHRONIZER RING SET (for 1st Gear)
Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring and outer ring) with gear oil.
Install the inner ring to the 1st gear.
*a | Outer Ring |
*b | Middle Ring |
*c | Inner Ring |
Install the middle ring to the 1st gear.
Engage the claws of the middle ring to the grooves of the 1st gear.
Install the outer ring to the 1st gear.
Align the claws of the inner ring with the grooves of the outer ring before installing the outer ring.
INSTALL NO. 1 TRANSMISSION CLUTCH HUB
Install the No. 1 transmission clutch hub to the output shaft.
Align the cutout of the No. 1 transmission clutch hub with the protrusion of the outer ring as shown in the illustration.
INSTALL NO. 1 SYNCHROMESH SHIFTING KEY
Install the 3 No. 1 synchromesh shifting keys to the No. 1 transmission clutch hub.
INSTALL REVERSE GEAR
Coat the reverse gear and No. 1 transmission clutch hub with gear oil.
Install the reverse gear to the No. 1 transmission clutch hub.
Install the reverse gear as shown in the illustration.
INSTALL NO. 1 SYNCHRONIZER RING SET (for 2nd Gear)
Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring and outer ring) with gear oil.
Install the outer ring to the No. 1 transmission clutch hub.
Align the protrusion of the outer ring with the cutout of the No. 1 transmission clutch hub before installing the outer ring.
Install the middle ring to the outer ring.
Install the inner ring to the middle ring.
Align the cutout of the outer ring with the protrusion of the inner ring before installing the inner ring.
*a | Inner Ring |
*b | Middle Ring |
*c | Cutout |
INSTALL INNER 2ND GEAR BEARING RACE
Coat the inner 2nd gear bearing race with gear oil and install it to the output shaft.
INSTALL 2ND GEAR NEEDLE ROLLER BEARING
Coat the 2nd gear needle roller bearing with gear oil and install it to the output shaft.
INSTALL 2ND GEAR
Coat the 2nd gear with gear oil and install it to the output shaft.
*a | Claw |
*b | Groove |
Align the claw of the middle ring with the groove of the 2nd gear before installing the 2nd gear.
INSTALL 3RD DRIVEN GEAR
Using SST and a press, install the 3rd driven gear to the output shaft.
INSTALL OUTPUT GEAR SPACER
Install the output gear spacer to the output shaft.
INSTALL 4TH DRIVEN GEAR
Using SST and a press, install the 4th driven gear to the output shaft.
INSTALL 5TH DRIVEN GEAR
Using SST and a press, install the 5th driven gear to the output shaft.
INSTALL OUTPUT GEAR SPACER
Install the output gear spacer to the output shaft.
INSTALL 6TH DRIVEN GEAR
Using SST and a press, install the 6th driven gear to the output shaft.
INSTALL REAR OUTPUT SHAFT BEARING
Using SST and a press, install a new rear output shaft bearing to the output shaft.
INSPECT 2ND GEAR RADIAL CLEARANCE
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INSPECT 1ST GEAR RADIAL CLEARANCE
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INSPECT 2ND GEAR THRUST CLEARANCE
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INSPECT 1ST GEAR THRUST CLEARANCE
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