MAINSHAFT W/Input Shaft: Assembly

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

Fig 1: Installing 6th Gear Needle Bearing & Gear On Mainshaft
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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 2: Installing Clutch Body & Synchronizer Ring

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Install the clutch body (2) and the synchronizer ring (1).
Assemble the synchronizer if it is not being replaced. See SYNCHRONIZER .
Press on the 5th/6th gear synchronizer assembly (1).

Fig 3: Pressing On 5th/6th Gear Synchronizer Assembly
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NOTE: Snap rings that are bent or otherwise damaged must be replaced.

Fig 4: Installing Snap Ring On Mainshaft

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Install the snap ring (1) on the mainshaft (2). Check that it is fully seated.
Install the synchronizer ring (2). Be sure the drivers on the synchronizer ring are engaged in the grooves of the synchronizer body.

Fig 5: Installing Synchronizer Ring
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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 6: Installing Cylindrical Bearing In The Input Shaft & Placing Input Shaft On Mainshaft
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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 7: Installing Second Gear Needle Bearing & Second Gear On Mainshaft With Collar Facing Upwards
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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).

Fig 8: Installing Friction Ring, Cone Ring & Synchronizer Ring
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Assemble the 1st/2nd gear synchronizer if it is not being replaced. See SYNCHRONIZER .
Install the 1st/2nd gear synchronizer assembly (1).

Fig 9: Installing 1st/2nd Gear Synchronizer Assembly
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NOTE: Do not over expand the snap ring.

Fig 10: Installing Snap Ring

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Install the snap ring (1).

NOTE: The lobes on the friction ring (1) must engage in the recesses in the synchronizer ring (3).

Fig 11: Installing Synchronizer Ring, Cone Ring & Friction Ring

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Install the synchronizer ring (3), the cone ring (2), and the friction ring (1).
Install the first gear needle bearing (3), first gear (2), and press on the 1st gear thrust washer (1).

Fig 12: Installing First Gear Needle Bearing, First Gear & Pressing On 1st Gear Thrust Washer
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Press on the sleeve (2), and the reverse gear needle bearing (1).

Fig 13: Pressing On Sleeve & Reverse Gear Needle Bearing
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NOTE: The reverse gear collar must face upwards.

Fig 14: Installing Reverse Gear & Synchronizer Ring

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Install the reverse gear (2), and the synchronizer ring (1).
Press on the reverse gear synchronizer assembly (1).

Fig 15: Pressing On Reverse Gear Synchronizer Assembly
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Remove the input shaft together with the mainshaft from the vise.
Assemble the geartrain housing. See GEARTRAIN HOUSING .