Mainshaft Disassembly/Inspection/Reassembly

Exploded View





5-speed model





6-speed model

Disassembly

NOTE: 6-speed model is shown, 5-speed model is similar.





1. Remove the angular ball bearing (A) and the tapered cone ring using a commercially available bearing separator (B) and a commercially available bearing puller (C). Be sure the bearing separator is under the tapered cone ring. (5-speed model).





2. Support 5th gear (A) on steel blocks, and press the mainshaft out of the 5th/6th synchro hub (B). Use of a jaw-type puller can damage the gear teeth.





3. Support the 3rd gear (A) on steel blocks, and press the mainshaft out of the 3rd/4th synchro hub (B). Use of a jaw-type puller can damage the gear teeth.

Inspection





1. Inspect the gear surface and bearing surface for wear and damage, then measure the mainshaft at points A, B, and C. If any part of the mainshaft is less than the service limit, replace it with a new one.





2. Inspect the runout by supporting both ends of the mainshaft. Rotate the mainshaft two complete revolutions when measuring the runout. If the runout is more than the service limit, replace the mainshaft with a new one.

Reassembly

Special Tools Required
- Driver, 40 mm I.D. 07746-0030100
- Attachment, 30 mm I.D. 07746-0030300

NOTE:
- Refer to the Exploded View as needed during this procedure.
- 6-speed model is shown, 5-speed model is similar.

1. Clean all the parts in solvent, dry them, and apply lubricant to all contact surfaces except the 3rd/4th and 5th/6th synchro hubs.
2. Install the needle bearing on the mainshaft.





3. Install the double cone synchro assembly (A) by aligning the synchro cone fingers (B) with the holes in 3rd gear (C), then install the synchro spring (D).





4. Install the 3rd/4th synchro hub (A) by aligning the synchro cone fingers (B) with the grooves in 3rd/4th synchro hub (C).





5. Install the 3rd/4th synchro hub (A) using the special tool.





6. Install the 3rd/4th synchro sleeve (A) by aligning the stops (B) with the 3rd/4th synchro sleeve and hub. After installing, check the operation of the 3rd/4th synchro hub set.





7. Install the synchro spring (A).
8. Install the double cone synchro assembly (B) by aligning the synchro cone fingers (C) with the grooves in 3rd/4th synchro hub (D).





9. Install the 4th gear (A) by aligning the synchro cone fingers (B) with holes in 4th gear (C).
10. Install the needle bearings, distance collar, and 5th gear.





11. Install the double cone synchro assembly (A) by aligning the synchro cone fingers (B) with the holes in 5th gear (C), then install the synchro spring (D).





12. Install the 5th/6th synchro hub (A) by aligning the synchro cone fingers (B) with the grooves in 5th/6th synchro hub (C).





13. Install the 5th/6th synchro hub (A) using the special tools.
14. Install the 5th/6th synchro sleeve.
15. Install the distance collar and the taper cone ring (5-speed model).





16. Install the synchro spring (A).
17. Install the double cone synchro assembly (B) by aligning the synchro cone fingers (C) with the grooves in 5th/6th synchro hub (D).
18. Install the distance collar and the needle bearing.





19. Install the 6th gear (A) by aligning the synchro cone fingers (B) with the holes in 6th gear (C).





20. Install the new ball bearing (A) using the special tools and a press (B).