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MAINSHAFT AND COUNTER SHAFT COMPONENTS ASSEMBLY

BHE051117040M03

1. Assemble in the order indicated in the table.

1 | Mainshaft
2 | Bearing
3 | 2nd gear
4 | Inner cone
5 | Double cone
6 | Synchronizer ring (2nd)
7 | Synchronizer ring component (2nd) (See Synchronizer Ring Component Assembly Note.)
8 | 1st/2nd clutch hub
9 | Synchronizer key
10 | Clutch hub sleeve
11 | Synchronizer key spring
12 | 1st/2nd clutch hub component (See Clutch Hub Component (1st/2nd, 3rd/4th) Assembly Note.)
13 | 3rd gear
14 | Bearing
15 | Inner cone
16 | Double cone
17 | Synchronizer ring (3rd)
18 | Synchronizer ring component (3rd) (See Synchronizer Ring Component Assembly Note.)
19 | 3rd/4th clutch hub
20 | Synchronizer key
21 | Clutch hub sleeve
22 | Synchronizer key spring
23 | 3rd/4th clutch hub component (See Clutch Hub Component (1st/2nd, 3rd/4th) Assembly Note.)
24 | Snap ring
25 | Synchronizer ring (4th)
26 | Inner cone
27 | Double cone
28 | Synchronizer ring (1st)
29 | Synchronizer ring component (1st) (See Synchronizer Ring Component Assembly Note.)
30 | Bearing race
31 | Bearing
32 | 1st gear
33 | Countershaft center bearing race (See Countershaft Center Bearing Race Assembly Note.)
34 | Friction gear
35 | Diaphram spring
36 | Countershaft front bearing spacer (See Countershaft Front Bearing Spacer Assembly Note.)
37 | Countershaft

## Synchronizer Ring Component Assembly Note

1. Assemble the inner cone, double cone and synchronizer ring as shown in the figure.

## Clutch Hub Component (1st/2nd, 3rd/4th) Assembly Note

  Caution

  • Be sure to assemble the clutch hub components and synchronizer ring components while aligning the synchronizer ring grooves with the synchronizer keys.
  • The standard synchronizer key dimensions are as follows:

13B-MSP

mm {in}

| 1 | 2 | 3
1st/2nd | 17.0 {0.670} | 4.7 {0.185} | 5.0 {0.197}
3rd/4th | 17.0 {0.670} | 4.25 {0.167} | 5.0 {0.197}

13B-Turbo

mm {in}

| 1 | 2 | 3
1st/2nd | 18.0 {0.709} | 5.45 {0.215} | 6.0 {0.236}
3rd/4th | 17.0 {0.670} | 4.25 {0.167} | 5.0 {0.197}

EXCEPT 13B-MSP, 13B-Turbo

mm {in}

| 1 | 2 | 3
1st/2nd, 3rd/4th | 17.0 {0.670} | 4.25 {0.167} | 5.0 {0.197}

  Caution

  • Be sure to install each clutch hub component onto the mainshaft in the proper direction.

  Caution

  • Be sure to align the synchronizer ring projections with the inner cone notches.
  • Be sure to assemble the gears and the synchronizer ring components while aligning the double cone projections with the gear holes as shown in the figure.

1. Using a press, assemble the needle bearing, 2nd gear, synchronizer ring component (2nd), 1st/2nd clutch hub component to the mainshaft.

  Caution

  • When using a press, be careful not to damage the parts.

2. Set the needle bearing, 3rd gear, synchronizer ring (3rd) and 3rd/4th clutch hub component on the mainshaft, then press them onto the mainshaft using the SST.

3. Install a new snap ring on the front of the mainshaft.

## Countershaft Center Bearing Race Assembly Note

1. Assemble the countershaft center bearing race using the SSTs.

## Countershaft Front Bearing Spacer Assembly Note

  Note

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