MAINSHAFT W/Input Shaft: Assembly

Fig 1: Removing/Installing 6th Gear Idler Gear & Needle Bearing

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Install the 6th gear needle bearing (2) and gear (1) on the mainshaft (3).

Fig 2: Removing/Installing Synchronizer Cone & Clutch Body
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Install the clutch body (2) and the synchronizer ring (1).
NOTE: The inscription on the synchronizer body must face upwards (towards the input end). The drivers on the synchronizer ring must engage in the grooves in the synchronizer body.

Fig 3: Installing 5th/6th Gear Synchronizer Assembly
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Assemble the synchronizer if it is not being replaced. (Refer to TRANSMISSION/TRANSAXLE/MANUAL/SYNCHRONIZER - ASSEMBLY) .
Press on the 5th/6th gear synchronizer assembly (1).

Fig 4: Installing Snap Ring
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NOTE: Snap rings that are bent or otherwise damaged must be replaced.
Install the snap ring (1) on the mainshaft (2). Check that it is fully seated.

Fig 5: Installing Synchronizer Ring
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Install the synchronizer ring (2). Be sure the drivers on the synchronizer ring are engaged in the grooves of the synchronizer body.

Fig 6: Installing Cylindrical Bearing & Input Shaft
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Oil the cylindrical bearing (2) and place it in the input shaft (1).
Place the input shaft (1) on the mainshaft.

Fig 7: Installing Second Gear Needle Bearing & Second Gear
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Invert the mainshaft with input shaft in the vise. Use protected vise jaws.
Install the second gear needle bearing (3), and second gear (2) on the mainshaft (1) with the collar facing upwards.

Fig 8: Installing Friction Ring, The Cone Ring, & Synchronizer Ring
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Install the friction ring (4), the cone ring (3), and the synchronizer ring (2). The lobes in the friction ring (4) must engage in the recesses of the synchronizer ring (3).
Assemble the 1st/2nd gear synchronizer if it is not being replaced. (Refer to TRANSMISSION/TRANSAXLE/MANUAL/SYNCHRONIZER - ASSEMBLY) .

Fig 9: Installing 1st/2nd Gear Synchronizer Assembly
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Install the 1st/2nd gear synchronizer assembly (1).

Fig 10: Installing Snap Ring
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NOTE: Do not over expand the snap ring.
Install the snap ring (1).

Fig 11: Installing Synchronizer Ring, Cone Ring & Friction Ring
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NOTE: The lobes on the friction ring (1) must engage in the recesses in the synchronizer ring (3).
Install the synchronizer ring (3), the cone ring (2), and the friction ring (1).

Fig 12: Installing First Gear Needle Bearing, First Gear, & 1st Gear Thrust Washer
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Install the first gear needle bearing (3), first gear (2), and press on the 1st gear thrust washer (1).

Fig 13: Installing Sleeve & Reverse Gear Needle Bearing
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Press on the sleeve (2), and the reverse gear needle bearing (1).

Fig 14: Removing/Installing Reverse Gear Synchronizer Ring & Idler Gear
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NOTE: The reverse gear collar must face upwards.
Install the reverse gear (2), and the synchronizer ring (1).

Fig 15: Removing/Installing Reverse Gear Synchronizer Assembly
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Press on the reverse gear synchronizer assembly (1).
Remove the input shaft together with the mainshaft from the vise.
Assemble the geartrain housing. (Refer to TRANSMISSION/TRANSAXLE/MANUAL/GEARTRAIN HOUSING - ASSEMBLY) .