1. When the sleeve and hub assemblies have been disassembled, reassemble by aligning the alignment marks.
NOTE:
Position the open ends of the spring 120° apart.
|
(A) |
3rd-4th hub ASSY |
|
(B) |
3rd gear side |
2. Install the needle bearing, 3rd drive gear, outer baulk ring, 3rd synchro cone, inner baulk ring and 3rd-4th synchronizer hub on the transmission main shaft.
NOTE:
Align the groove in baulk ring with the shifting insert.
|
(A) |
3rd needle bearing |
|
(B) |
3rd drive gear |
|
(C) |
Inner baulk ring |
|
(D) |
3rd synchro cone |
|
(E) |
Outer baulk ring |
|
(F) |
3rd-4th synchronizer hub |
3. Install the 4th needle bearing race onto transmission main shaft using ST1, ST2, ST3 and a press.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
| ST1 899714110 | REMOVER |
| ST2 499877000 | RACE 4-5 INSTALLER |
| ST3 398177700 | INSTALLER |
|
(A) |
4th needle bearing race |
4. Install the 3rd-4th coupling sleeve, 4th baulk ring, needle bearing, 4th drive gear and 4th gear thrust washer to the transmission main shaft.
NOTE:
• Align the 4th baulk ring and 3rd-4th synchronizer hub with the key groove.
• Install the 3rd-4th coupling sleeve with the groove side facing the 3rd drive gear.
• Install the 4th gear thrust washer with the groove side facing the 4th drive gear.
|
(A) |
Groove |
|
(B) |
Face this surface to the 4th gear side. |
|
(A) |
3rd-4th coupling sleeve |
|
(B) |
4th baulk ring |
|
(C) |
4th drive gear |
|
(D) |
Needle bearing |
|
(E) |
4th gear thrust washer |
5. Install the double taper roller bearing into the rear section of transmission main shaft using ST1, ST2 and a press.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE:
Install the double taper roller bearing with snap ring side facing the 5th drive gear side.
| ST1 899714110 | REMOVER |
| ST2 499877000 | RACE 4-5 INSTALLER |
6. Install the 5th needle bearing race into the rear section of transmission main shaft using ST1, ST2 and a press.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
| ST1 899714110 | REMOVER |
| ST2 499877000 | RACE 4-5 INSTALLER |
|
(A) |
5th needle bearing race |
7. Install the needle bearing, 5th drive gear, 5th baulk ring, and 5th-6th synchronizer hub on the transmission main shaft.
NOTE:
• Align the protruded section of 5th baulk ring with concave section of 5th-6th synchronizer hub.
• Install the 5th-6th synchronizer hub with the groove side facing the 5th drive gear.
|
(A) |
5th-6th synchronizer hub |
|
(B) |
5th baulk ring |
|
(C) |
5th drive gear |
|
(A) |
5th-6th synchronizer hub |
|
(B) |
5th baulk ring |
|
(C) |
5th drive gear |
|
(D) |
Needle bearing |
8. Install the 6th needle bearing race onto transmission main shaft using ST1, ST2 and a press.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
| ST1 899714110 | REMOVER |
| ST2 499877000 | RACE 4-5 INSTALLER |
|
(A) |
6th needle bearing race |
9. Install the 5th-6th coupling sleeve, 6th baulk ring, 6th drive gear and needle bearing on the transmission main shaft.
NOTE:
Install the 5th-6th coupling sleeve with the short flange side facing the 5th drive gear.
|
(A) |
6th baulk ring |
|
(B) |
5th-6th coupling sleeve |
|
(C) |
5th-6th shifting insert key |
|
(D) |
Face this side to 5th gear (short flange side) |
|
(A) |
5th-6th coupling sleeve |
|
(B) |
6th baulk ring |
|
(C) |
6th drive gear |
|
(D) |
Needle bearing |
10. Install the ball bearing onto transmission main shaft using ST2 and a press.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE:
Install the ball bearing with the side which does not have lock nut mounting dent facing 6th drive gear.
| ST1 899714110 | REMOVER |
| ST2 899754112 | PRESS |
|
(A) |
Ball bearing |
11. Tighten the lock nuts to the specified torque using ST1 and ST2.
NOTE:
Lock nuts and lock washers must be replaced with new parts.
| ST1 499987003 | SOCKET WRENCH (35) |
| ST2 498937000 | TRANSMISSION HOLDER |
Tightening torque:
160 N·m (16.3 kgf-m, 118.0 ft-lb)
12. Crimp lock nuts in two locations after tightening.