MAINSHAFT AND GEAR

Assembly

1. Press in reverse main gear using Tools.

• Be careful with orientation of reverse main gear.

• Do not reuse reverse main gear.

2. Press in 1st main gear bushing using Tools.

3. Install 1st needle bearing and then 1st main gear.
4. Install 1st-2nd spread spring, 1st-2nd shifting insert, and 1st-2nd synchronizer hub onto 1st-2nd coupling sleeve.

CAUTION:

• Be careful with orientation of 1st-2nd synchronizer hub.

• Do not reuse 1st-2nd synchronizer hub and 1st-2nd coupling sleeve.
• Replace 1st-2nd synchronizer hub and 1st-2nd coupling sleeve as a set.

• Be careful with orientation of 1st-2nd coupling sleeve.
• Be sure not to hook center projection of 2 spread springs on same 1st-2nd shifting insert.

5. Install 1st inner baulk ring, 1st synchronizer cone, and 1st outer baulk ring onto mainshaft and then press in 1st-2nd synchronizer hub assembly onto mainshaft using Tools.

• Outer baulk ring, synchronizer cone, and inner baulk ring on 2nd gear-side must have been removed.
• Be careful with orientation of coupling sleeve.
• Replace 1st inner baulk ring, 1st synchronizer cone, and 1st outer baulk ring as a set.

6. Press in 2nd main gear bushing using Tools.

7. Install 2nd outer baulk ring, 2nd synchronizer cone, and 2nd inner baulk ring.

CAUTION:
Replace 2nd outer baulk ring, 2nd synchronizer cone, and
2nd inner baulk ring as a set.

8. Install 2nd needle bearing and 2nd main gear.

9. Press in 3rd main gear using Tools.

• Be careful with orientation of 3rd main gear.
• Do not reuse 3rd main gear.

10. Install 3rd-4th mainshaft spacer.
11. Select 4th main gear adjusting shim so that dimension "C1" satisfies the standard value below and install 4th main gear adjusting shim onto mainshaft.

Standard value for dimension "C1" : Refer to See: Specifications\Mechanical\Dimension.

CAUTION:
Only one adjusting shim can be selected.

12. Press in 4th main gear using Tools.

• Be careful with orientation of 4th main gear.
• Do not reuse 4th main gear.

13. Press in 5th main gear using Tools.

• Be careful with orientation of 5th main gear.
• Do not reuse 5th main gear.

14. Install 5th-6th mainshaft spacer.

15. Press in 6th main gear using Tools (A) and (B).

16. Select 6th main gear adjusting shim and then install it onto mainshaft.

• Calculate thickness "S" of 6th main gear adjusting shim following the procedure below so that end play dimension between 6th main gear and mainshaft rear bearing becomes the dimension shown below.

1. Measure dimension "S1" and "S2" using a height gauge (A) and pick tester (B).
2. Install selected 6th main gear adjusting shim to mainshaft.

17. Press in mainshaft rear bearing using Tools.

18. Install mainshaft C-ring onto mainshaft and check that end play of mainshaft rear bearing satisfies the standard value.

End play standard value : Refer to See: Specifications\Mechanical\End Play.

• If measurement is outside the standard range, reselect mainshaft C-ring.

19. Install C-ring holder and then install snap ring.

CAUTION:
Do not reuse snap ring.

20. Check end play of 1st and 2nd main gears.

End play standard value : Refer to See: Specifications\Mechanical\End Play.