Tools Required

Important: Coat the inner parts of the gear, the bearing and the oil seal with gear fluid.

1. Install the 1st gear bearing (2).
2. Install the 1st gear (3).
3. Install the 1st gear synchronizer ring (1).



4. Install the 1st-2nd synchronizer springs to hub.

Important: There is a difference of key groove width between the 1st synchronizer ring and the 2nd synchronizer ring.

Specifications:

•	The key groove width for the 1st synchronizer rings-A (1) is 8.2 mm (0.323 in).

•	The key groove width for the 2nd synchronizer ring-B (2) is 9.6 mm (0.378 in).





Important: Ensure A=B when installing the keys.

5. Install the 1st-2nd synchronizer keys to hub.
6. Install the hub (2) to the sleeve (1).




Important: Position the synchronizer key to the 1st gear synchronizer ring groove.

7. Insert the 1st-2nd synchronizer hub assembly into the counter shaft using DT 46496  (1), KM-466-A  (2), and a hammer.




Important: Position the 2nd synchronizer ring groove to the synchronizer hub key.

8. Install the 2nd synchronizer ring.
9. Install the 1st-2nd gear synchronizer circlip.



10. Install the 2nd gear bearing (2).
11. Install the 2nd gear (1).



12. Insert the 3rd gear and the 3rd-4th gear spacer into the counter shaft.
13. Install the 3rd-4th gear spacer (2) using DT 46493 and a hammer.
14. Install the 3rd gear spacer (3) using the gear, bearing installer DT 46493 and a hammer.



15. Install the 4th gear (2) to the counter shaft using DT 46495 and a hammer (1).



16. Install the left side bearing (2) to the counter shaft using DT 46495  (1) and a hammer.



17. Install the counter shaft right side bearing.
18. Install the gear unit. Refer to Transmission Assemble.