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TRANSMISSION CASE COMPONENTS ASSEMBLY

BHE051117030M05

1. Assemble in the order indicated in the table.

1 | Transmission case (See Transmission Case Assembly Note .)
2 | Mainshaft gear component
3 | 1st/2nd shift fork
4 | 3rd/4th shift fork
5 | Bearing
6 | Main drive gear
7 | Countershaft component
8 | Thrust washer
9 | Adjustment shim
10 | Mainshaft front bearing (See Mainshaft Front Bearing Assembly Note.)
11 | Countershaft center bearing (See Countershaft Center Bearing Assembly Note.)
12 | Main drive gear bearing (See Main Drive Gear Bearing Assembly Note.)
13 | Adjustment shim
14 | Countershaft front bearing (See Countershaft Front Bearing Assembly Note.)
15 | Snap ring

## Transmission Case Assembly Note

1. Adjust the mainshaft front bearing end play.

  (1) Measure dimension D using a vernier caliper.
  (2) Measure dimension E using a vernier caliper.

  Formula: T = D - E
  T: Mainshaft front bearing end play
  D: Depth of mainshaft front bearing bore in the transmission case
  E: Mainshaft front bearing snap ring height
  Standard: 0-0.05 mm {0-0.002 in}

  (3) If not within the specification, adjust by choosing the proper adjustment shim.

| Thickness (mm {in})
--- | ---
Adjustment shim | 0.1 {0.004}
0.3 {0.012}

2. Adjust the countershaft front bearing end play.

  (1) Measure dimension B using a vernier caliper.
  (2) Measure dimension A using a vernier caliper.

  Formula: T = A - B + adjustment shim thickness
  T: Countershaft front bearing end play
  A: Countershaft front bearing snap ring height
  B: Depth of countershaft front bearing bore in the transmission case
  Standard: 0-0.1 mm {0-0.004 in}

  (3) If not within the specification, adjust by choosing the proper adjustment shim.

| Thickness (mm {in})
--- | ---
Adjustment shim | 0.1 {0.004}
0.3 {0.012}

3. Assemble the 1st/2nd shift fork and 3rd/4th shift fork to the clutch hub component.

4. Apply specified grease to the needle bearing and assemble it to the main drive gear.

5. Assemble the main drive gear onto the front of the mainshaft.

6. Assemble the countershaft component to the transmission case.

7. Verify that the countershaft gears engage each gear of the mainshaft.

## Mainshaft Front Bearing Assembly Note

1. Install the adjustment shim onto the rear of the mainshaft.

  Caution

  • Be sure to install the adjustment shim selected during the mainshaft front bearing end play adjustment.

2. Assemble the mainshaft front bearing using the SSTs.

## Countershaft Center Bearing Assembly Note

1. Assemble the countershaft center bearing onto the rear of the countershaft using the SSTs.

## Main Drive Gear Bearing Assembly Note

1. Install the SST between the 4th gear synchronizer ring and main drive synchromesh gear.

2. Assemble the main drive gear bearing using the SSTs.

## Countershaft Front Bearing Assembly Note

  Note

  • When replacing the countershaft front bearing, replace the spacer.

1. Install the adjustment shim onto the countershaft front bearing.

  Caution

  • Be sure to install the adjustment shim selected during the countershaft front bearing end play adjustment.

2. Assemble the countershaft front bearing using the SSTs.

3. Assemble new snap rings to the main drive gear and countershaft gear.

  Note

  • The counter drive gear side snap ring is smaller than the main drive gear side snap ring.