Primary Shaft: Reassembly
- To reassemble, reverse disassembly procedure. Measure clearance after each component is installed. See TRANSAXLE COMPONENT CLEARANCE SPECIFICATIONS table.See Figure.
- Select correct synchronizer keys. See SYNCHRONIZER KEY DIMENSIONS table. See Fig 1. Install keys and spring in synchronizer hub. Install synchronizer assembly with bevel facing away from input end of primary shaft. Locate synchronizer rings on correct clutch assembly.
SYNCHRONIZER KEY DIMENSIONS
| Synchro | Dimension 1 | Dimension 2 | Dimension 3 |
|---|---|---|---|
| 1st/2nd | 0.748 (19.00) | 0.167 (4.25) | 0.197 (5.00) |
| 3rd/4th | 0.669 (17.00) | 0.167 (4.25) | 0.197 (5.00) |
| 5th/Rev. | 0.669 (17.00) | 0.167 (4.25) | 0.197 (5.00) |
TRANSAXLE COMPONENT CLEARANCE SPECIFICATIONS
| Application | Standard: In. (mm) | Maximum: In. (mm) | |||
|---|---|---|---|---|---|
| Primary Shaft | |||||
| 3rd-To-2nd Gear | .002-.008 (.05-.20) | .010 (.25) | |||
| 4th Gear-To-Bearing | |||||
| F25M-R | .008-.024 (.21-.61) | .026 (.66) | |||
| G25M-R | .006-.015 (.17-.37) | .017 (.42) | |||
| Secondary Shaft | |||||
| 1st Gear Thrust | .002-.011 (.05-.28) | .013 (.33) | |||
| 2nd-To-3rd Gear | |||||
| F25M-R | .007-.020 (.18-.51) | .22 (.56) | |||
| G25M-R | .007-.018 (.18-.46) | .020 (.50) | |||
| 1st/2nd Hub-To-Shift Fork | |||||
| F25M-R | .004-.014 (.10-.36) | .036 (.86) | |||
| G25M-R | .004-.018 (.10-.45) | .029 (.73) | |||
| 3rd/4th Hub-To-Shift Fork | |||||
| F25M-R | .008-.020 (.20-.50) | .039 (1.0) | |||
| G25M-R | .004-.016 (.10-.40) | .039 (1.00) | |||
| 5th/Reverse | |||||
| Hub-To-Shift Fork | |||||
| F25M-R | .016-.030 (.40-.75) | .049 (1.24) | |||
| G25M-R | .004-.014 (.10-.36) | .038 (.96) | |||
| Synchronizer-To-Gear | .059 (1.50) | .031 (.80) | |||
| Reverse Idler Gear-To-Shift Lever | .004-.013 (.10-.32) | .015 (.37) | |||
| Primary Shaft Run Out | N/A | .002 (.05) | |||
| Secondary Shaft Run Out | N/A | .0006 (.015) | |||
| Oil Clearance Between Shafts & Gears | .001-.003 (.03-.08) | .003 (.08) | |||