Spark

Counter Gear Shaft Assemble

Special Tools

For equivalent regional tools, refer to Special Tools

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

1. Install the 1st gear spacer (1).
2. Install the 1st gear bearing (2).
3. Install the 1st gear (3).
4. Install the 1st gear synchroniser ring (4).




Note: Make sure that the key units is properly seated into the key groove of sleeve and hub.

5. Install the hub (2) to the 1st-2nd gear synchroniser sleeve (1).
6. Install the key units (3) into the key groove of the hub and sleeve.




Note:  Match the key groove of hub to the 1st gear synchroniser ring lug.

7. Install the 1st-2nd gear synchroniser hub assembly (2) into the layshaft using theDT-49081 gear, bearing installation tool (1), and hammer.



8. Install the 1st-2nd gear synchroniser circlip (2).

Note: Match the 2nd synchroniser ring lug to the key groove of hub.

9. Install the 2nd synchroniser ring (1).



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



12. Insert the 3rd gear and the 3rd-4th gear spacer into the layshaft.
13. Install the 3rd-4th gear spacer (2) and the 3rd gear (3) using the DT-49079 gear, bearing installation tool (1) and a hammer.



14. Install the 4th gear (2) to the layshaft using the DT-49080 gear, bearing installation tool (1) and a hammer.



15. Install the left side bearing (2) onto the layshaft using the DT-49080 gear, bearing installation tool (1) and hammer.



16. Install the layshaft right side bearing.
17. Install the gear unit. Refer to Transmission Assemble .