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MAIN DRIVE GEAR AND MAINSHAFT COMPONENT ASSEMBLY

BHE051117050105

1. Assemble in the order indicated in the table.

2. Verify the following after assembly.

  (1) The gear rotates smoothly when rotated by hand.
  (2) The synchronizer ring is not stuck.

1 | Main drive gear
2 | Bearing (See Bearing Assembly Note.)
3 | Snap ring (bearing) (See Snap Ring (Bearing) Assembly Note.)
4 | Synchronizer ring
5 | Needle bearing
6 | Clutch hub
7 | Synchronizer key
8 | Synchronizer key spring
9 | Steel ball
10 | Clutch hub sleeve
11 | Mainshaft
12 | Needle bearing
13 | Reverse gear
14 | Synchronizer ring
15 | Clutch hub component (5th/reverse) (See Clutch Hub Component (5th/reverse) Assembly Note.)
16 | Snap ring (reverse gear) (See Snap Ring (Reverse Gear) Assembly Note.)
17 | Needle bearing
18 | 2rd gear
19 | Inner ring
20 | Middle ring
21 | Synchronizer ring
22 | Clutch hub component (1st/2nd) (See Clutch Hub Component (1st/2nd) Assembly Note.)
23 | Steel ball
24 | Synchronizer ring
25 | Middle ring
26 | Inner ring
27 | 1st gear
28 | Needle bearing
29 | Inner race
30 | Bearing
31 | 6th gear (See 6th Gear Assembly Note.)
32 | Snap ring (6th gear) (See Snap Ring (6th Gear) Assembly Note.)
33 | Main drive gear component

## Bearing Assembly Note

1. Install the bearing using the SSTs.

## Snap Ring (Bearing) Assembly Note

1. Install the snap ring removed during disassembly, and measure the clearance between the snap ring and the installation groove using a feeler gauge.

2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the main drive gear.

  Clearance
  0-0.1 mm {0-0.0039 in}

Snap Ring size

mm {in}

Identification mark | Thickness | Identification mark | Thickness
--- | --- | --- | ---
0 | 1.95 {0.077} | 3 | 2.10 {0.083}
1 | 2.00 {0.079} | 4 | 2.15 {0.085}
2 | 2.05 {0.081} | 5 | 2.20 {0.087}

## Clutch Hub Component (5th/reverse) Assembly Note

1. Securely align the tab on the synchronizer ring with the key groove of the clutch hub.

  Caution

  • Do not damage the synchronizer ring when installing the clutch hub component.

2. Carefully install the clutch hub component (5th/reverse) using the SSTs and a press.

## Snap Ring (Reverse Gear) Assembly Note

1. Install the snap ring removed during disassembly, and measure the clearance between the snap ring and the installation groove using a feeler gauge.

2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the mainshaft.

  Clearance
  0-0.1 mm {0-0.0039 in}

Snap Ring size

mm {in}

Identification mark | Thickness | Identification mark | Thickness
--- | --- | --- | ---
A | 1.80 {0.071} | D | 1.95 {0.077}
B | 1.85 {0.073} | E | 2.00 {0.079}
C | 1.90 {0.075} | F | 2.05 {0.081}

## Clutch Hub Component (1st/2nd) Assembly Note

1. Securely align the tab on each ring with the installation hole of the 2nd gear and the key groove of the clutch hub.

  Caution

  • Do not damage each synchronizer ring when installing the clutch hub component.

2. Carefully install the clutch hub component (1st/2nd) using the SSTs and a press.

## 6th Gear Assembly Note

1. Install the bearing and 6th gear using the SSTs and a press.

## Snap Ring (6th Gear) Assembly Note

1. Install the snap ring removed during disassembly, and measure the clearance between the snap ring and the installation groove using a feeler gauge.

2. Select the new snap ring from the following table so that the clearance measured in Step 1 is within specification, and install it in the mainshaft.

  Clearance
  0-0.11 mm {0-0.0043 in}

Snap Ring size

mm {in}

Identification mark | Thickness | Identification mark | Thickness
--- | --- | --- | ---
A | 2.67 {0.105} | G | 3.03 {0.119}
B | 2.73 {0.107} | H | 3.09 {0.122}
C | 2.79 {0.110} | J | 3.15 {0.124}
D | 2.85 {0.122} | K | 3.21 {0.126}
E | 2.91 {0.115} | L | 3.27 {0.129}
F | 2.97 {0.117} | - | -