Necessary equipment
- DT-48240 Secondary Shaft 5th/Reverse Synchronizer Installation Tool
- DT-48239 Secondary Shaft 5th Gear Bearing Ring Installer
- DT-48237 Secondary Shaft 3rd/4th Gear Installer
Assembly order
Important: Before installation, lubricate all components with transmission fluid.
1. Install the thrust ring using DT-48240 and a hydraulic press.
2. Install the ring using DT-48240 and a hydraulic press.
3. Install the needle bearings (3).
4. Install the reverse gear (2).
5. Install the reverse gear locking ring (1).
6. Install the 5th/Reverse synchronizer using DT-48240 and a hydraulic press.
Important:
- The raised center hub of the 5th/Reverse synchronizer assembly faces the 5th gear pinion.
- When pressing, align the locking ring protrusions and hub grooves in line.
7. Install the bearing ring using DT-48239 and a hydraulic press.
8. Install the 5th gear locking ring (3).
9. Install two needle bearings (2).
10. Install the 5th gear pinion (1).
11. Install 3rd gear using DT-48237 and hydraulic press.
Important: The 3rd gear pinion is very tightly installed. Make sure the mating surfaces are clean.
12. Apply locking sealant before installing 4th gear pinion (Permatex 620) on the circumference of the primary shaft.
13. Install the 4th gear using DT-48237 and a hydraulic press.
Important: The 4th gear is very tightly installed. Make sure the mating surfaces are clean.