Disassembly and assembly sequence: Assembling

The transmission is assembled in reverse order of disassembly. Pay particular attention to the following points:

Installation position of 1st gear thrust washer: shoulder -A- on inner diameter faces bearing cover -B-

Fig 1: Identifying Installation Position Of 1st Gear Thrust Washer

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Installation position of operating sleeve/synchronizer hub for 1st/2nd gear: groove on face -A- and outside teeth on operating sleeve -B- face 1st gear -C-

Fig 2: Identifying Installation Position Of Operating Sleeve/Synchronizer Hub For 1st/2nd Gear

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• Heat 1st/2nd gear operating sleeve/synchronizer hub to approx. 100 °C (212 °F), then place in position and drive firmly into place while turning synchronizer ring so that grooves align with keys.
• Install reverse idler gear, driving shaft in gently if necessary.
Fig 3: Installing Reverse Idler Gear
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• Drive inner race of 2nd gear needle bearing on to stop.
Fig 4: Driving Inner Race Of 2nd Gear Needle Bearing On To Stop
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• Install needle bearing, synchronizer ring, 2nd gear and 3rd gear.

  Installation position on 3rd gear: shoulder (arrow) faces 2nd gear -A-

Fig 5: Identifying Installation Position On 3rd Gear
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• Adjust axial clearance on 3rd gear as follows:
  • Determine thickest circlip that can be inserted (available circlips, see AVAILABLE CIRCLIPS ), and install.
Fig 6: Adjusting Axial Clearance On 3rd Gear
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