Assembling, Through Transmission Build Date 25 October 2009

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Fig 1: Identifying Inner Ring Gap

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-- Check the tabs on the inner race for scoring.

-- Install the inner race onto the taper of the selector gear and then measure the gap dimension -a- with a feeler gauge.

Gap dimension -a-	Installed dimension	Wear limit
1st, 2nd and 3rd gear	0.75 to 1.25 mm	0.3 mm

Fig 2: Identifying Check Of 1st, 2nd And 3rd Gear Synchro - Rings For Wear

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-- Install the synchronizer ring, outer race and inner race onto the taper of the selector gear and then measure the gap dimension -a- with a feeler gauge.

Gap dimension -a-	Installed dimension	Wear limit
1st, 2nd and 3rd gear	1.2 to 1.8 mm	0.5 mm

-- Install the 2nd gear with the needle bearing.

Fig 3: Exploded View Of Modified 1st Gear Synchronization Components (From Transmission Build Date 02 05 0)

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-- Check the tabs -arrows 1 and 2- for scoring.

-- Replace the inner race, the outer race and the synchronizer ring if they have grooves or scoring.

-- Install the inner race -A- on the 2nd gear.

The angled tabs -arrows 1- face the outer race -B-.

-- Install the outer race -B-.

The tabs -arrows 2- must lock into the retainers -arrows 3- in the gear.

-- Install the synchronizer ring -C-.

The retainers -arrows 4- lock in the tabs -arrows 1- on the inner race -A-.

Fig 4: Exploded View Of Gear Locking Collar And Synchro-Hub Components

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Spring
Locking piece
Locking collar
Synchronizer hub

-- Slide the locking collar over the synchronizer hub.

In 3rd and 4th gear, the wide collar on the synchronizer hub and the locking collar face in one direction.

The notches for the locking pieces on the synchronizer hub and locking collar must line up with each other.

Fig 5: Identifying 3rd And 4th Gear Locking Collar/Synchro-Hub

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The locking collar is pushed over the synchronizer hub.

-- Install the locking pieces and springs offset by 120°. The angled end of the spring must engage into the hollow locking piece.

Fig 6: Installation Position Of 1st And 2nd Gear Locking Collar/Synchro-Hub

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The identification groove -arrow 1- and the narrow collar -arrow 2- on the synchronizer hub face 1st gear.

Fig 7: Identifying Tool Assembly To Press On 1st And 2nd Gear Locking Collar/Synchro-Hub

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Turn the synchronizer ring so that the grooves line up with the locking pieces.

-- Install the locking ring.

Install the 1st gear synchronizer ring

Fig 8: Installation Position For 1st Or 3rd Gear Outer Ring

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The tabs -arrows- face the synchronizer hub/locking collar -A-.

Fig 9: Installation Location Of Synchronizer Ring (Inner Race For 1st And 3rd Gear)

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The tabs -arrows 1- engage into the holes -arrows 2- inside the synchronizer ring -B-.

Fig 10: Installation Position 1st And 3rd Gear Wheel

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The higher collar -A- faces the 2nd gear -B-. The notches in the collar -arrow- lock into the tabs on the outer race. Refer to Fig 8.

-- Install the thrust washers for 1st and 4th gears, refer to "Thrust Washers" in item 19 and "Washer" in item 20.

-- Install the 4th gear with needle bearing.

Fig 11: Identifying Check Of 4th Gear Synchro-Ring For Wear

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-- Press the synchronizer ring onto the taper of the gear and measure the gap dimension -a- using a feeler gauge.

Gap dimension -a-	Installed dimension	Wear limit
4th gear	1.0 to 1.7 mm	0.5 mm

Fig 12: Installation Position 3rd And 4th Gear Locking Collar/Synchro-Hub

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The wider collar on the synchronizer hub -arrow- faces 3rd gear.

Fig 13: Identifying Tool Assembly To Press On 3rd And 4th Gear Synchro-Hub With Locking Collar

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-- Turn the synchronizer ring so that the grooves line up with the locking pieces.

-- Install the locking ring.

-- Install the 3rd gear synchronizer ring on the synchronizer hub/locking collar for 3rd and 4th gears.

Fig 14: Installation Position For 1st Or 3rd Gear Outer Ring

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The tabs -arrows- face the synchronizer hub/locking collar -A-.

Fig 15: Installation Location Of Synchronizer Ring (Inner Race For 1st And 3rd Gear)

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The tabs -arrows 1- engage into the holes -arrows 2- inside the synchronizer ring -B-.

Fig 16: Installation Position 1st And 3rd Gear Wheel

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The higher collar -A- faces toward the 4th gear -B-. The notches in the collar -arrow- lock into the tabs on the outer race. Refer to Fig 8.

-- Install the 3rd gear with the needle bearing.

NOTE:

Pressing on the inner race/tapered roller bearing. Refer to Figure.

Selecting the locking ring for the inner race/tapered roller bearing. Refer to Figure.