10. Mainshaft Reassembly

Mainshaft Reassembly

Mainshaft 5-speed model:

Mainshaft 2002-2003 6-speed models, and 2004 6-speed model:

Mainshaft 2004 6-speed model, and 2005-2006 speed models:

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

NOTE: Refer to the Exploded View as needed during this procedure.

1. Clean all the parts in solvent, dry them and apply lubricant to all contact surfaces except the 3rd/4th and 5th synchro hubs.
2. Install the needle bearing and 3rd gear on the mainshaft.
3. 5-speed model: Install the synchro ring (A) and the synchro spring (B).





4. 6-speed model: 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).





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





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





7. 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.





8. Install the synchro spring (A).

5-speed model:





6-speed model:





9. Install the synchro ring (B) (5-speed model) or the double cone synchro assembly (B) (6-speed model) by aligning the synchro ring fingers (C) with the grooves in the 3rd/4th synchro hub (D).
10. 5-speed model: Install 4th gear (A).





11. 6-speed model: Install 4th gear (A) by aligning the synchro cone finger's (B) with the holes in 4th gear (C).





12. Install the needle bearings, the distance collar, and 5th gear.
13. 5-speed model, 2004 6-speed model: X2M5 Transmission Number: 3004680 or later, and 2005-2006 6-speed models: Install the synchro ring (A) and synchro spring (B).





14. 2002-2003 6-speed models, and 2004 6-speed model: X2M5 Transmission Number: 3000001-3004679: 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).





15. Install the 5th synchro hub (A) by aligning the synchro ring grooves (B) with the fingers in the 5th synchro hub (C).





16. Install the 5th synchro hub (A) using the special tools.





17. 5-speed model: Install the 5th synchro sleeve.
18. 6-speed model: Install the 5th/6th synchro sleeve.
19. 5-speed model, and 2004 6-speed model: X2M5 Transmission Number: 3004680 or later, 2005-2006 6-speed models: Install the synchro spring (A). Install the synchro ring (B) by aligning the synchro cone fingers (C) with the grooves in the 5th synchro hub (5-speed model) or 5th/6th synchro hub (6-speed model) (D).





20. 2002-2003 6-speed models, and 2004 6-speed model: X2M5 Transmission Number: 3000001-3004679: Install the synchro spring W. Install the double cone synchro assembly (B) by aligning the synchro ring fingers (C) with the grooves in the 5th/6th synchro hub (D).





21. 5-speed model: Install the MBS distance collar and tapered cone ring.
22. 6-speed model: Install the distance collar and the needle bearing.
23. 2002-2003 6-speed models, and 2004 6-speed model: X2M5 Transmission Number 3000001-3004679: Install 6th gear (A) by aligning the synchro cone fingers (B) with the holes in 6th gear (C).





24. 2004 6-speed model: X2M5 Transmission Number: 3004680 or later, and 2005-2006 6-speed models: Install the 6th gear (A).





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