Input and Output Shaft to Intermediate Plate Assembly

Input and Output Shaft to Intermediate Plate Assembly

Install the output shaft (10) into the intermediate plate (11) by pulling on the output shaft and tapping on the intermediate plate.





Install the input shaft (12) to the output shaft with the synchronizer ring slots aligned with the shifting keys.

Install the counter gear (13) into the intermediate plate while holding the oounter gear, and install the counter rear bearing with a suitable driver.





Install the bearing snap ring (14) using snap ring pliers.

NOTE: Be sure the snap ring is flush with the intermediate plate surface.

Using a Torx bit, install and tighten the screws (15) to 18 Nm (13 ft-lbs) torque.





Install the reverse shift arm bracket (16) and tighten the bolts to 18 N~m (13 ft-lbs) torque.

Install the ball and spacer.





Install the shifting keys and hub sleeve No.3 (18) onto the counter 5th gear (17).

CAUTION: Install the key springs positioned so the end gaps are not in line.

Install shifting key springs under the shifting keys.





Apply gear oil to the needle roller bearing and install the counter 5th gear with hub sleeve No.3 (19) and needle roller bearings.





Install the synchronizer ring (20) on gear spline piece No.5 (21).

Using tool J-28406 drive in gear spline piece No.5 with the synchronizer ring slots aligned with the shifting keys.

NOTE: When installing gear spline piece No.5, support the counter gear in front with a 3 - 5 lb hammer or equivalent.





Engage two gears to lock (K) the output shaft.

Install and tighten the lock nut (21) to 122 Nm (90 ft-lbs) torque on the counter shaft (21).

Stake the lock nut.

Disengage the gears.





Measure the counter fifth gear thrust clearance (L) using a feeler gauge.

Standard Clearance: 0.10-0.30 mm (0.004 - 0.012 in)