Disassembly

DISASSEMBLY




1. Disassemble the geartrain housing.
2. Mount the main shaft in a vise with protective jaws.
3. Remove first gear idler gear using special tool 938 and 1126.




4. Remove the reverse gear synchronizer assembly (1).




5. Remove the synchronizer ring (1) and idler gear (2) for reverse gear.




6. Remove first gear needle bearing (1) and sleeve (2).




7. Remove the thrust washer (1), first gear idler gear (2), and first gear idler needle bearing (3).




8. Remove the friction ring (1), cone ring (2), and the synchronizer ring (3).




9. Remove the locking ring (1) using pliers. Remove the 1st/2nd gear synchronizer using special tool 938 and 1126.




10. Remove the synchronizer ring (1), cone ring (2), and friction ring (3).




11. Remove the second gear idler gear (1) and needle bearing (2).




12. Remove the main shaft (1) from the input shaft (2).
13. Remove the synchronizer ring (5) and the clutch body (4).
14. Remove the cylindrical roller bearing (3) from the input shaft (2).
15. Remove the input shaft (2) from the vise.




16. Clamp the main shaft (3) in the vise with input end up.
17. Remove the locking ring (1), pull off the synchronizer cone (2) and the clutch body using special tool 938 and 1126.




18. Remove the synchronizer ring (1) and the clutch body (2).




19. Remove the 6th gear idler gear (1) and needle bearing (2).
20. Remove the main shaft (3) from the vise.