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TRANSMISSION CASE AND 6TH GEAR COMPONENT ASSEMBLY

BHE051117010105

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 is not stuck.

1 | Push pin (See Push Pin Assembly Note (BP))
2 | Pressure spring
3 | Spring pin (See Spring Pin Assembly Note (BP))
4 | Clutch hub
5 | Synchronizer key
6 | Synchronizer key spring
7 | Steel ball
8 | Retaining ring
9 | Clutch hub sleeve
10 | Steel ball
11 | Shift rod (See Shift Rod Assembly Note.)
12 | Transmission case (See Transmission Case Assembly Note.)
13 | Pressure spring, steel ball
14 | Snap ring (rear)
15 | Snap ring (front)
16 | Bolt and gasket (See Bolt and Gasket Assembly Note.)
17 | Bolt
18 | Plug
19 | Oil seal (See Oil Seal Assembly Note.)
20 | Front cover
21 | Interlock sleeve
22 | Inner shift lever (See Inner Shift Lever Assembly Note.)
23 | Bearing cover component
24 | Pin
25 | Thrust washer
26 | Needle bearing
27 | 6th gear
28 | Synchronizer ring
29 | Clutch hub component (6th) (See Clutch Hub Component (6th) Assembly Note.)
30 | Snap ring (See Snap Ring Assembly Note.)
31 | Steel ball
32 | 6th shift fork (See 6th Shift Fork Assembly Note.)
33 | Steel ball, pressure spring
34 | Plug
35 | Spring pin
36 | Plug (See Plug Assembly Note.)

## Push Pin Assembly Note (BP)

1. Install the push pin so that its notch faces in the direction shown in the figure.

## Spring Pin Assembly Note (BP)

1. Secure the bearing cover component compressing the pressure spring using the SST.

2. Drive the spring pin.

## Shift Rod Assembly Note

1. Install the SST into the clutch housing.

2. Install the steel ball into the shift arm (5th).

3. Taking care so that the steel ball does not drop out, carefully insert the shift rod until it contacts the SST installed to the clutch housing.

4. Turn the notch of the shift rod end toward the shift rod A.

## Transmission Case Assembly Note

1. Set the shift operation system to the neutral position.

  Note

  • If the countershaft center bearing interferes with the transmission case when installing, pry the roller of the bearing lightly using a screw driver covered with a rag.

2. Install the pressure spring and steel ball into the transmission case, then install the transmission case onto the clutch housing pressing with a pin punch so that the steel ball does not spring out.

## Bolt and Gasket Assembly Note

1. Tighten the transmission case mounting bolt, then tighten the new gasket and bolt A (for the reverse idler shaft).

2. Tighten bolt B tightened temporarily on the clutch housing.

  Tightening torque (Bolt A and B)
  24-33 N·m {2.5-3.3 kgf·m, 18-24 ft·lbf}

## Oil Seal Assembly Note

1. Install the new oil seal in the front cover using the SSTs and a hammer.

## Inner Shift Lever Assembly Note

1. Install the inner shift lever using a suitable pipe and a hammer.

## Clutch Hub Component (6th) 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 (6th) using the SST.

## Snap Ring 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 countershaft gear.

  Clearance
  0-0.1 mm {0-0.0039 in}
  Snap ring size
mm {in}

Identification mark | Thickness | Identification mark | Thickness
--- | --- | --- | ---
A | 2.80 {0.110} | D | 2.95 {0.116}
B | 2.85 {0.112} | E | 3.00 {0.118}
C | 2.90 {0.114} | F | 3.05 {0.120}

## 6th Shift Fork Assembly Note

1. Install the 6th shift fork in the clutch hub component.

2. Insert the steel ball from the transmission case.

3. Pass the SST through the 6th shift fork and install in the shift rod.

4. Pull the SST up, then install the steel ball, pressure spring and plug from outside of the transmission case and secure the shift rod.

## Plug Assembly Note

1. Remove the SST installed to the clutch housing, and install the plug.