5-speed model:
6-speed model:
Special Tools Required
Driver, 40 mm I.D. ( 07746-0030100)
| 1. | Clean all the parts in solvent, dry them, and apply lubricant to all contact surfaces except the 3rd/4th and 5th/6th synchro hubs. |
| 2. | Install the needle bearing and 3rd gear on the mainshaft. |
| 3. | Install the double cone synchro assembly (A) by aligning the synchro cone fingers (B) with the holes in 3rd gear (C), then install the synchro spring (D). |
| 4. | Install the 3rd/4th synchro hub (A) by aligning the synchro cone fingers (B) with the grooves in 3rd/ 4th synchro hub (C). |
| 5. | Install the 3rd/4th synchro hub (A) using the special tool. |
| 6. | Install the 3rd/4th synchro sleeve (A) by aligning the stops (B) with the 3rd/4th synchro sleeve and hub. After installing, check the operation of the 3rd/4th synchro hub set. |
| 7. | Install the synchro spring (A). |
| 8. | Install the double cone synchro assembly (B) by aligning the synchro cone fingers (C) with the grooves in 3rd/4th synchro hub (D). |
| 9. | Install 4th gear (A) by aligning the synchro cone fingers (B) with holes in 4th gear (C). |
| 10. | Install the needle bearings, distance collar, and 5th gear. |
| 11. | Install the double cone synchro assembly (A) by aligning the synchro cone fingers (B) with the holes in 5th gear (C), then install the synchro spring (D). |
| 12. | Install the 5th/6th synchro hub (A) by aligning the synchro cone fingers (B) with the grooves in 5th/6th synchro hub (C). |
| 13. | Install the 5th/6th synchro hub (A) using the special tools. |
| 14. | Install the 5th/6th synchro sleeve. |
| 15. | Install the distance collar and the tapered cone ring ( 5-speed model). |
| 16. | Install the synchro spring (A). |
| 17. | Install the double cone synchro assembly (B) by aligning the synchro cone fingers (C) with the grooves in 5th/6th synchro hub (D). |
| 18. | Install the distance collar and the needle bearing. |
| 19. | Install the 6th gear (A) by aligning the synchro cone fingers (B) with the holes in 6th gear (C). |
| 20. | Install the new ball bearing (A) using the special tools and a press (B). |