Main Shaft Assembly: Assembly

Assemble sleeve and hub assembly for 3rd-4th and, 5th synchronizing.
NOTE: Position open ends of spring 120° apart.

Fig 1: Assembling Sleeve And Hub Assembly For 3rd-4th and, 5th Synchronizing
Install 3rd drive gear, outer baulk ring, synchro cone, inner baulk ring, sleeve and hub assembly for 3rd needle bearing on transmission main shaft.
NOTE: Align groove in baulk ring with shifting insert.

Fig 2: Installing 3rd Drive Gear Assembly
Install 4th needle bearing race onto transmission main shaft using ST1, ST2 and a press.
CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

Fig 3: Installing 4th Needle Bearing Race
Install baulk ring, needle bearing (32 x 30 x 25.7), 4th drive gear and 4th gear thrust washer to transmission main shaft.
NOTE: Align baulk ring and gear & hub assembly with key groove.

Fig 4: Aligning Baulk Ring, Gear & Hub Assembly With Key Groove
Drive ball bearing onto the rear section of transmission main shaft using ST1, ST2 and a press.
CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

Fig 5: Driving Ball Bearing Onto The Rear Section Of Transmission Main Shaft
Using ST1 and ST2, install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft.
CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).

NOTE: Face thrust washer in the correct direction.

ST1 899714110 REMOVER

ST2 499877000 RACE 4-5 INSTALLER

Fig 6: Installing 5th Gear Thrust Washer And 5th Needle Bearing Race
Install bearing onto synchro cone.
NOTE: Align baulk ring and gear & hub assembly with key groove.
Install baulk ring and synchro cone onto 5th-Rev sleeve and hub assembly using ST and a press.
CAUTION: Do not apply pressure in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE:
- Use new ball bearing.
- After press fitting, make sure synchro cone rotates freely.
ST 499757002 SNAP RING PRESS

Fig 7: Installing Baulk Ring And Synchro Cone
Install synchro cone stopper and snap ring to 5th-Rev sleeve and hub assembly.

Fig 8: Installing Synchro Cone Stopper And Snap Ring
Install the rest parts to the rear section of transmission main shaft.
NOTE: Align groove in baulk ring with shifting insert.

ST1 499987003 SOCKET WRENCH

ST2 498937000 TRANSMISSION HOLDER

Fig 9: Installing The Remaining Parts
Tighten lock nuts to the specified torque using ST1 and ST2.
NOTE: Secure lock nuts in two places after tightening.

ST1 499987000 SOCKET WRENCH

ST2 498937000 TRANSMISSION HOLDER

Tightening torque:
1. 118 N.m (12.0 kgf-m, 86.8 ft-lb)