PRIMARY SHAFT COMPONENTS ASSEMBLY

BME051517201M04

1. Assemble in the order indicated in the table.

1
Primary shaft
2
3rd needle bearing
3
3rd gear
4
3rd synchronizer ring
5
3rd/4th synchronizer key spring
6
3rd/4th synchronizer key
7
3rd/4th clutch hub and sleeve
8
3rd/4th clutch hub set
9
4th synchronizer ring
10
4th bushing
11
4th needle bearing
12
4th gear
13
Primary shaft thrust washer
14
5th bushing
15
5th needle bearing
16
5th gear
17
5th synchronizer ring
18
5th synchronizer key spring
19
5th synchronizer key
20
5th clutch hub and sleeve
21
5th clutch hub set
22
5th gear stopper
23
Primary shaft bearing spacer
24
Snap ring
25
Primary shaft rear bearing
26
Primary shaft front bearing
27
Oil channel
28
Primary shaft rear bearing adjust shim

3rd/4th Synchronizer Key Spring, 3rd/4th Synchronizer Key and 3rd/4th Clutch Hub and Sleeve Assembly Note

1. Install the 3rd/4th synchronizer key spring, 3rd/4th synchronizer key and 3rd/4th clutch hub to the 3rd/4th clutch sleeve.

(1) Install a new 3rd/4th clutch hub in the direction as shown in the figure.

(2) Install a new 3rd/4th clutch sleeve in the direction as shown in the figure.

(3) Install center projection parts of 3rd/4th synchronizer key springs to different synchronizer keys on each side.

3rd/4th Clutch Hub Set Assembly Note

Note
• Align the synchronizer ring grooves with the synchronizer key during assembly.

1. Install the 3rd/4th clutch hub set using the SSTs.

4th Bushing Assembly Note

1. Install the 4th bushing using the SSTs.

Primary Shaft Thrust Washer Assembly Note

1. Install the primary shaft thrust washer using the SSTs.

2. Measure length C1 as shown in the figure.

• If not within the specification, adjust it by selecting a proper thrust washer from below.
• Select only one thrust washer.
Specification C1
154.7-154.8 mm {6.091-6.094 in}

Primary shaft thrust washer size

Thickness (mm {in})

3.84 {0.151}
4.02 {0.158}
3.90 {0.154}
4.08 {0.161}
3.96 {0.156}
4.14 {0.163}

5th Bushing Assembly Note

1. Install a new 5th bushing using the SSTs.

5th Synchronizer Key Spring, 5th Synchronizer Key and 5th Clutch Hub and Sleeve Assembly Note

1. Assembly the 5th synchronizer key springs, 5th synchronizer key and 5th clutch hub to the 5th clutch sleeve.

(1) Install a new 5th clutch hub in the direction as shown in the figure.

(2) Install a new 5th clutch sleeve in the direction as shown in the figure.

(3) Install center projection parts of 5th synchronizer key springs to different synchronizer keys on each side.

5th Clutch Hub Set Assembly Note

Note
• Align the synchronizer ring grooves with the synchronizer key during assembly.

1. Install the 5th clutch hub set using the SSTs.

Primary Shaft Bearing Spacer Assembly Note

1. Install the primary shaft bearing spacer using the SSTs.

Snap Ring Assembly Note

1. Install a new snap ring to the primary shaft.

2. Measure the clearance between the snap ring and the primary shaft bearing spacer.

• If not within the specification, adjust it by selecting a proper snap ring from below.
Clearance
0.0-0.1 mm {0.0000-0.0039 in}

Snap ring size

Thickness (mm {in})

1.71 {0.067}
2.01 {0.079}
1.76 {0.069}
2.06 {0.081}
1.81 {0.071}
2.11 {0.083}
1.86 {0.073}
2.16 {0.085}
1.91 {0.075}
2.21 {0.087}
1.96 {0.077}
2.26 {0.089}

Primary Shaft Rear Bearing Assembly Note

1. Place the primary shaft rear bearing with the brown side facing toward the 5th gear.

2. Install the primary shaft rear bearing using the SSTs.

Primary Shaft Front Bearing Assembly Note

1. Install the primary shaft front bearing using the SSTs.

2. Inspect the 3rd gear and 5th gear thrust clearance and 4th gear end play. (See PRIMARY SHAFT COMPONENTS PREINSPECTION.)