1. When the sleeve and hub assemblies have been disassembled, reassemble by aligning the alignment marks.
NOTE:
Position the open ends of the spring 120° apart.
|
(A) |
High-low coupling sleeve |
|
(B) |
Shifting insert |
|
(C) |
High-low synchronizer spring |
|
(D) |
High-low synchronizer hub |
|
(E) |
Sleeve |
|
(F) |
Insert key |
|
(G) |
3rd-4th synchronizer hub |
|
(H) |
High side |
|
(I) |
Low side |
|
(J) |
3rd side |
|
(K) |
4th side |
2. Install the 3rd drive gear, outer baulk ring, synchro cone, inner baulk ring, and sleeve and hub assembly for the 3rd needle bearing, on the transmission main shaft. (Except for 1.5 L model)
NOTE:
Align the groove in baulk ring with the shifting insert.
|
(A) |
3rd needle bearing |
|
(B) |
3rd drive gear |
|
(C) |
Inner baulk ring |
|
(D) |
Synchro cone |
|
(E) |
Outer baulk ring |
|
(F) |
Sleeve & hub ASSY |
3. Install the 3rd drive gear, baulk ring, 3rd needle bearing sleeve and hub assembly to the transmission main shaft. (1.5 L model)
NOTE:
Align the groove in baulk ring with the shifting insert.
4. Install the 4th needle bearing race onto transmission main shaft using ST1, ST2 and press.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
| ST1 899714110 | REMOVER |
| ST2 499877000 | RACE 4-5 INSTALLER |
|
(A) |
4th needle bearing race |
5. Install the baulk ring, needle bearing, 4th drive gear and 4th gear thrust washer to the transmission main shaft.
NOTE:
Align the baulk ring and sleeve and hub assembly with the key groove.
|
(A) |
Groove |
|
(B) |
Face this surface to the 4th gear side. |
6. Press-fit the ball bearing into the rear section of transmission main shaft using ST1, ST2 and a press.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
| ST1 899714110 | REMOVER |
| ST2 499877000 | RACE 4-5 INSTALLER |
7. Using the ST1 and ST2, install the 5th gear thrust washer (non-turbo model) and 5th needle bearing race onto the rear section of transmission main shaft.
CAUTION:
Do not apply a load in excess of 10 kN (1 ton, 1.1 US ton, 1.0 Imp ton).
NOTE:
Make sure the thrust washer is facing the correct direction.
| ST1 899714110 | REMOVER |
| ST2 499877000 | RACE 4-5 INSTALLER |
|
(A) |
Face this surface to the 5th gear side. |
8. Install rest of the parts to the rear section of the transmission main shaft.
CAUTION:
• Install the baulk lever so that the concave side faces toward the 5th hub.
|
(A) |
Baulk lever |
|
(B) |
5th hub |
• Align the protruded section of baulk ring between the baulk levers.
|
(A) |
Baulk ring |
|
(B) |
Baulk lever |
|
(C) |
5th hub |
|
(A) |
Needle bearing |
|
(B) |
5th drive gear |
|
(C) |
Baulk ring |
|
(D) |
5th hub & sleeve No. 2 |
|
(E) |
Lock washer |
|
(F) |
Lock nut |
|
(G) |
Baulk lever |
9. Tighten the lock nuts to the specified torque using ST1 and ST2.
NOTE:
Use new lock nuts and lock washers.
10. Crimp lock nuts in two locations after tightening.
| ST1 499987003 | SOCKET WRENCH (35) |
| ST2 498937000 | TRANSMISSION HOLDER |
Tightening torque:
120 N·m (12.2 kgf-m, 88.5 ft-lb)
11. Attach the needle bearing to the main shaft.
12. Install rest of the parts to the front section of the transmission main shaft.
NOTE:
• When installing the needle bearing, make sure not to damage the raised section on the transmission main shaft
• Face the grooved side towards the input gear.
• Align the groove of the high-low baulk ring to the shifting insert.
|
(A) |
Ball |
|
(B) |
Input low gear spacer |
|
(C) |
Needle bearing |
|
(D) |
Input low gear |
|
(E) |
Friction damper |
|
(F) |
High-low baulk ring |
|
(G) |
Sleeve & hub ASSY |
13. Using the ST1 and ST2, install the new snap ring to the rod section of the transmission main shaft.
NOTE:
Select an appropriate outer snap ring, so that the clearance between the snap ring and hub will become between 0.060 — 0.100 mm (0.0024 — 0.0039 in).
| ST1 499757002 | INSTALLER |
| ST2 499757001 | SNAP RING GUIDE |
|
Snap ring | |
|
Part No. |
Thickness mm (in) |
|
805025051 |
2.42 (0.0953) |
|
805025052 |
2.47 (0.0972) |
|
805025053 |
2.52 (0.0992) |
|
805025054 |
2.57 (0.1012) |
|
805025055 |
2.62 (0.1031) |
|
805025056 |
2.67 (0.1051) |
|
805025057 |
2.72 (0.1071) |
|
805025058 |
2.37 (0.0933) |