Assembly

Assemble in the order shown in the illustration, referring to the following notes:








Clutch Hub
Install the synchronizer keys and springs in the clutch hub.





Bearing (Secondary Shaft End)
Install the new secondary shaft end bearing by using the Special Service Tool (SST).





1st Gear, 1st Synchronizer Ring And 1st/2nd Clutch Hub Assembly
NOTE: The 2nd synchronizer ring has teeth missing at three places around its outer edge to help distinguish it from the other synchronizer rings.





1. Assemble the 1st gear, 1st synchronizer ring, and 1st/2nd clutch hub assembly.
2. Align the synchronizer ring grooves and synchronizer keys.





3. Press the 1st/2nd clutch hub assembly on by using the SST.





2nd Synchronizer Ring, 2nd Gear And Secondary 3rd Gear
1. Install the 2nd synchronizer ring and 2nd gear.
2. Install the secondary 3rd gear by using the SSTs.





Secondary 4th Gear And Bearing
1. Install the secondary 4th gear and the bearing by using the SST.





2. Measure the clearance between the 1st gear and the differential drive gear. Clearance should be within 0.05 - 0.28 mm (0.002 - 0.011 inch) and the maximum is 0.33 mm (0.013 inch).





3. Measure the clearance between the 2nd gear and the secondary 3rd gear. Clearance should be 0.18 - 0.46 mm (0.007 - 0.018 inch) and a maximum of 0.51 mm (0.020 inch).
4. If not as specified, reassemble the secondary shaft assembly.