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5TH/REVERSE GEAR AND HOUSING PARTS ASSEMBLY

BHE051117030M03

1. Assemble in the order indicated in the table.

1 | Counter reverse gear
2 | Thrust washer
3 | Reverse idler gear
4 | Reverse idler gear shaft
5 | Thrust washer
6 | Bearing cover
7 | Thrust washer
8 | Bearing race
9 | Bearing
10 | Reverse gear
11 | Reverse synchronizer ring (See Synchronizer Ring Assembly Note.)
12 | 5th/reverse clutch hub component (See 5th/Reverse Clutch Hub Component Assembly Note.)
13 | Locknut
14 | Synchronizer ring (5th) (See Synchronizer Ring Assembly Note.)
15 | Retaining ring
16 | 5th gear (See 5th Gear Assembly Note.)
17 | Bearing
18 | Steel ball
19 | Thrust lock washer
20 | C-clip
21 | 1st/2nd shift rod (See Shift Fork, Shift Rod Assembly Note.)
22 | Interlock pin (large)
23 | Interlock pin (small)
24 | 3rd/4th shift rod (See Shift Fork, Shift Rod Assembly Note.)
25 | Interlock pin (large)
26 | 5th/reverse shift fork (See Shift Fork, Shift Rod Assembly Note.)
27 | Spring
28 | 5th/reverse shift rod (See Shift Fork, Shift Rod Assembly Note.)
29 | Retaining ring
30 | Spring cap, spring, detent ball
31 | Spring cap, spring, spring seat, detent ball
32 | Blind cover
33 | Center housing (See Center Housing Assembly Note.)
34 | Set bolt, packing
35 | Oil passage
36 | Spacer
37 | Counter 5th gear
38 | Countershaft rear bearing (See Countershaft Rear Bearing Assembly Note.)
39 | Locknut
40 | Mainshaft rear bearing (See Mainshaft Rear Bearing Assembly Note.)
41 | C-clip
42 | Bearing housing (See Bearing Housing Assembly Note.)
43 | Pin and retaining ring
44 | Spring
45 | Spring retainer
46 | Retaining ring
47 | 1st/2nd shift rod end (See Shift Rod End Assembly Note.)
48 | 3rd/4th shift rod end (See Shift Rod End Assembly Note.)
49 | 5th/reverse shift rod end (See Shift Rod End Assembly Note.)
50 | Oil passage

## Synchronizer Ring Assembly Note

1. Identify the 5th and reverse synchronizer rings according to the identification marks and assemble.

| Identification mark
--- | ---
5th | One tooth missing in three places around its circumference
Reverse | None

## 5th/Reverse Clutch Hub Component Assembly Note

  Caution

  • Be sure to assemble the 5th/reverse clutch hub component and 5th/reverse synchronizer ring while aligning the synchronizer ring grooves with the synchronizer keys.
  • The standard synchronizer key dimensions are as follows:
mm {in}

| 1 | 2 | 3
--- | --- | --- | ---
5th/reverse | 17.0 {0.67} | 4.25 {0.17} | 5.0 {0.20}

  Caution

  • Be sure to assemble the 5th/reverse clutch hub component to the mainshaft so that the chamfered side faces the vehicle front as shown in the figure.

1. Shift the clutch hub sleeves to engage the 1st and 4th gears.

2. Install a new locknut using the SST.

  Tightening torque
  157-235 N·m {16-24 kgf·m, 116-173 ft·lbf}

3. Measure clearance A between the synchronizer key and synchronizer ring.

  • If not within the specification, adjust by choosing the proper thrust washer on the front of the mainshaft front bearing.

  Standard
  0.66-2.0 mm {0.026-0.079 in}

| Thickness (mm {in})
--- | ---
Thrust washer | 2.5 {0.098}
3.0 {0.118}
3.5 {0.138}

  Caution

  • The total combined thickness of the front and rear thrust washers must equal 6.0 mm {0.236 in}.

4. Stake the locknut into the mainshaft groove.

## 5th Gear Assembly Note

1. Assemble a new retaining ring.

2. Install the synchronizer ring, 5th gear and bearing.

3. Install the steel ball and thrust lock washer.

4. Install the 3.0 mm {0.118 in} C-clip.

5. Measure the clearance (5th gear end play) between the thrust lock washer and C-clip.

  • If not within the specification, adjust by choosing the proper thrust lock washer.

  Standard
  0.1-0.2 mm {0.004-0.008 in}

| Thickness (mm {in})
--- | ---
Thrust lock washer | 6.2 {0.244}
6.3 {0.248}
6.4 {0.252}
6.5 {0.256}
6.6 {0.260}
6.7 {0.264}

  Caution

  • Be sure to measure the 5th gear end play with the C-clip pushed toward the 5th gear.

## Shift Fork, Shift Rod Assembly Note

  Note

  • The 3rd/4th shift rod is the longest.
  • The 5th/reverse shift rod has an extra hole for the roll pin at the rear of the rod.
  • When assembling the shift rods, set the detents toward the ball side.

1. Slide the 1st/2nd shift rod.

2. Assemble a new roll pin in the direction shown in the figure.

  Note

  • The interlock pins must be assembled as shown in the figure.

3. Slide the SSTs into the transmission case to guide the interlock pins, and insert the first pin.

4. Remove the SST (for 3rd/4th shift fork guide) from the transmission case.

5. Slide the 3rd/4th shift rod containing the interlock pin (small) into the transmission case.

6. Secure the 3rd/4th shift rod onto the fork with the new roll pin.

7. Insert the remaining interlock pin and remove the SSTs.

8. Assemble the 5th/reverse fork to the clutch hub.

9. Assemble the 5th/reverse shift rod in the transmission case through the spring.

10. Install a new retaining ring using the SST.

11. Assemble a new roll pin in the direction as shown in the figure and secure the 5th/reverse shift fork to the shift rod.

12. Assemble the blind covers, wiring harness clip and new gaskets.

  Tightening torque
  7.8-12 N·m
  {80-120 kgf·cm, 70-104 in·lbf}

13. Install new packing, detent balls, spring seats, springs and spring caps.

  Tightening torque
  A: 39-59 N·m
  {4.0-6.0 kgf·m, 29-43 ft·lbf}
  B: 19-25 N·m
  {1.9-2.6 kgf·m, 14-18 ft·lbf}

## Center Housing Assembly Note

1. Apply sealant to the contact surfaces of the transmission case and center housing as shown in the figure.

2. Install the oil passage to the center housing.

3. Install the center housing.

4. Align the reverse idler gear shaft with the set bolt hole, and install the packing and set bolt.

  Tightening torque
  8.8-14 N·m
  {90-140 kgf·cm, 79-121 in·lbf}

5. Assemble the spacer and counter 5th gear.

## Countershaft Rear Bearing Assembly Note

1. Assemble the countershaft rear bearing using the SSTs.

2. Install the SST to the mainshaft and secure it in a vise.

3. Shift the 1st/2nd shift rod and 5th/reverse shift rod to engage the 1st gear and reverse gear.

4. Tighten a new locknut.

  Tightening torque
  127-196 N·m
  {13-20 kgf·m, 95-144 ft·lbf}

5. Stake the locknut into the countershaft groove.

## Mainshaft Rear Bearing Assembly Note

1. Assemble the mainshaft rear bearing using the SST.

2. Install the C-clip.

3. Measure the clearance between C-clip and groove.

  • If not within the specification, adjust by choosing the proper C-clip.

  Standard
  0-0.1 mm {0-0.004 in}

| Thickness (mm {in})
--- | ---
C-clip | 2.9 {0.114}
3.0 {0.118}
3.1 {0.122}

## Bearing Housing Assembly Note

1. Apply sealant to the contact surfaces of the center housing and bearing housing as shown in the figure.

2. Assemble the bearing housing.

## Shift Rod End Assembly Note

1. Assemble the shift rod ends onto the proper shift rods, and secure them with new roll pins pointing in the direction shown in the figure.