5TH/6TH Gear And Transmission Housing Cover, Installing
Refer to TRANSMISSION HOUSING COVER AND 5TH/6TH GEAR, REMOVING ("Transmission Housing Cover and 5th/6th Gear, Removing") to get a list of the special tools needed.
- Make sure that the : 30-211A and the : T10323 are installed.
-- Secure the bolt from the : 30-211A with the nut -A-.
5th Gear Installation Position
The groove all the way around -arrow- faces the transmission housing.
-- Install the 5th gear.
5th Gear Synchronizer Ring and 6th Gear Synchronizer Ring, Checking
-- Push the synchronizer rings onto the gear assembly taper before reinstalling the 5th and 6th gear assemblies and the 5th and 6th gear synchronizer rings. Measure the gap dimension -a- with a feeler gauge.
| Gap Dimension -a- | Installed Dimension | Wear Limit |
|---|---|---|
| 5th/6th gear | 1.1 to 1.7 mm | 0.5 mm |
-- Install the 5th gear assembly with the needle bearing.
-- Place the 5th gear synchronizer ring on the gear assembly.
-- If disassembled, assemble the 5th/6th gear synchronizer hub/locking collar before installing. Refer to Fig 6 and Fig 5.
5th/6th Gear Synchronizer Hub/Locking Collar Installation Position
The ridge -arrow 1- faces the 6th gear.
The synchronizer hub mounts -arrow 2- are in line with the synchronizer ring locking pieces (arrows in the image below).
5th/6th Gear Synchronizer Rings with Locking Pieces arrows
-- Cover all openings in the transmission housing with a cloth to prevent foreign objects from getting into the transmission.
-- Install the 5th/6th gear synchronizer hub.
Make sure there is enough clearance when installing the synchronizer ring.
-- Warm the inner race/cylindrical roller bearing for the 6th gear assembly to a maximum of 100 °C (212 °F) and install it on the input shaft.
Wear safety gloves.
-- Install the 6th gear synchronizer ring.
-- Install the 6th gear assembly with the needle bearing.
The inner race/cylindrical roller bearing -B- and the thrust washer -A- are combined into one component.
-- Warm the inner race/cylindrical roller bearing to a maximum of 100 °C (212 °F) and install it on the input shaft.
Wear safety gloves.
-- Position the sleeve -A- on the 5th gear.
6th Gear Installation Position
The groove -B- faces away from the sleeve -A-.
>>Or<< the groove -arrow 1- near the collar -arrow 2- faces away from the sleeve -A- (also see previous image).
Wear safety gloves.
-- Warm the 6th gear to a maximum of 100 °C (212 °F) and install it.
-- Move the 5th/6th gear locking collar to neutral. The 6th gear assembly can then be turned when installing the 6th gear.
-- Install the 6th gear. Pay attention to the spline meshing of the 6th gear and the 6th gear assembly.
-- Warm the inner race/cylindrical roller bearing -A- to a maximum of 100 °C (212 °F) and install it on the output shaft.
-- Now loosen the support for the input shaft.
Use a thread tap to remove any locking fluid residue from the threaded holes for the bolts -A-, for the 5th/6th gear synchronizer hub and the 6th gear.
Otherwise, there is a risk of the bolts shearing off.
-- Tighten the bolts for the 5th/6th gear and synchronizer hub. Refer to OVERVIEW - TRANSMISSION HOUSING COVER AND 5TH/6TH GEAR .
-- To tighten the bolts -A-, engage two gears -arrows 1 through 3-.
-- The input shaft and the output shaft are blocked after both gears are engaged. Both bolts can be loosened now.
-- Install the 5th/6th gear shift fork.
5th/6th Gear, Adjusting
-- Engage 5th gear.
-- Loosen the bolt -1-.
-- Push the shift jaw and locking collar downward -arrows- and tighten the bolt -1- to the tightening specification.
- 5th gear is engaged.
- Measurement check: it must not be possible to insert a 0.2 mm feeler gauge between the locking collar and both shift segments -arrow- on the 6th gear side.
-- Repeat the adjusting procedure if necessary.
-- Engage 5th gear and then 6th gear.
The 5th/6th gear shift fork must have a small amount of play in the shift jaw when 5th or 6th gear is engaged.
-- Take out of gear.
- The locking collar must now be in neutral. The synchronizer ring must move freely.
-- Move through all the gears.
-- Apply the Sealing Compound evenly onto the sealing surface of the transmission housing cover.
-- Install the transmission housing cover. Refer to OVERVIEW - TRANSMISSION HOUSING COVER AND 5TH/6TH GEAR .
-- Install the release bearing guide sleeve. Refer to OVERVIEW - CLUTCH RELEASE MECHANISM .
-- Install the clutch release lever and release bearing. Refer to CLUTCH RELEASE MECHANISM, SERVICING .
-- Fill the transmission fluid. Refer to TRANSMISSION, INSTALLING .
Tightening Specifications
- Refer to OVERVIEW - TRANSMISSION HOUSING COVER AND 5TH/6TH GEAR
- Refer to OVERVIEW - SHIFT FORKS