Reverse and 5th Gear - Reassemble

Reverse And 5th Gear - Reassemble







1. Fit output shaft reverse gear selective washer, bush and needle bearing.
2. Fit output shaft reverse gear and synchromesh baulk ring.
3. Fit layshaft reverse gear.
4. Assemble selector spool, selector fork and reverse/5th gear synchromesh hub. Fit as one assembly to output shaft splines and selector shaft.

CAUTION: Ensure synchromesh baulk ring locates inside hub.

5. Fit new circlip.

NOTE: The fit of the circlip is controlled by the selective washer behind the reverse gear. Adjust to 0.005 - 0.055 mm (0.0002 - 0.002 in).

6. Fit 5th gear split needle bearing.
7. Fit 5th gear and 5th gear synchromesh baulk ring to output shaft, fit layshaft 5th gear.
8. Later gearboxes: Fit split washer to retain layshaft 5th gear.

NOTE: Bevelled side of washer must face towards gear.

9. Fit new output shaft thrust collar roll pin. Locate 5th gear thrust segments and retaining ring.







10. Using LRT-37-023 to hold layshaft 5th gear, fit a new layshaft stake nut and tighten to 220 Nm (162 ft. lbs.).
11. Stake layshaft 5th gear nut.







12. Using LRT-37-015 and LRT-37-021 press output shaft rear support bearing track to collar on output shaft.
13. Apply small amount of heat and fit layshaft rear support bearing.







14. Fit centre plate detent ball and spring.
15. Apply Loctite 290 to threads of detent plug, fit plug and tighten to 25 Nm (18 ft. lbs.).
16. Move selector shaft and check that detent balls can be felt to engage in detent.