Main Shaft

REMOVE OR DISCONNECT
^ Tools Required:
- J 34757 Circlip Remover
- J 22912-01 Split Plate

Important: The main shaft 1st gear and reverse gear bushings are identical as are the main shaft 1st and 2nd gear needle bearings. Make note of these components and their positions during disassembly to ensure correct assembly and operation.

1. High speed and reverse hub C-clip from main shaft using J 34757.





2. High speed synchronizer rings, high speed sleeve and hub assembly, main shaft 3rd gear and main shaft 3rd gear needle bearing from main shaft using J 22912-01 and press arbor.
3. High speed synchronizer sleeve from high speed synchronizer hub.
4. High speed synchronizer springs and three synchronizer keys from high speed synchronizer hub.





5. Two retaining rings and speedometer drive gear from main shaft using J 34757.
6. Main shaft rear bearing C-clip from main shaft using J 34757.





7. Main shaft rear bearing from main shaft using J 22912-01 and press arbor.

Important: The main shaft 5th gear and reverse gear needle bearings separate into two halves each. Make note of these components and their locations to ensure correct assembly and operation.

8. Main shaft 5th gear washer, main shaft washer ball, main shaft 5th gear, high speed synchronizer ring and main shaft 5th gear needle bearing from main shaft.
9. Reverse synchronizer sleeve from reverse synchronizer hub.
10. Reverse synchronizer springs and three synchronizer keys from reverse synchronizer hub.
11. High speed and reverse hub C-clip from main shaft using J 34757.





12. Reverse synchronizer hub from main shaft using J 22912-01 and a press arbor.
13. Main shaft reverse gear and needle bearing from main shaft.

NOTICE: DO NOT remove the main shaft bearing washer, main shaft reverse gear bushing and the main shaft center bearing in one step. The main shaft washer ball which locks the main shaft bearing washer in place could damage the main shaft or the main shaft center bearing. Remove the main shaft reverse gear bushing first, then, remove the main shaft bearing washer and main shaft washer ball before removing the bushing main shaft center bearing from the main shaft.

14. Main shaft reverse gear bushing, main shaft bearing washer and main shaft washer ball from the main shaft.
15. Main shaft center bearing from main shaft using J 22912-01 and press arbor.

NOTICE: DO NOT remove the main shaft bearing washer, main shaft 1st gear, main shaft 1st gear needle bearing and low speed synchronizer ring in one step. The main shaft washer ball which locks the main shaft bearing washer in place could damage the main shaft or the main shaft 1st gear. Remove the main shaft bearing washer and main shaft washer first, then, remove the main shaft 1st gear, main shaft 1st gear needle bearing and low speed synchronizer ring.

16. Main shaft bearing washer and main shaft washer ball from main shaft.
17. Main shaft 1st gear, main shaft 1st gear needle bearing and low speed synchronizer ring from main shaft.





18. Main shaft 1st gear bushing, low speed sleeve and hub assembly, low speed synchronizer ring and main shaft 2nd gear from main shaft using J 22912-01 and press arbor.
19. Main shaft 2nd gear needle bearing from main shaft.
20. Low speed synchronizer sleeve from low speed synchronizer hub.
21. Low speed synchronizer springs and synchronizer keys from low speed synchronizer hub.

Clean
- All main shaft components thoroughly with solvent and air dry.

Inspect





- All needle bearings for unusual wear or damage. Replace as necessary.
- All ball bearings for roughness or wear. Replace as necessary.
- Chamfered portion of each synchronizer ring for excessive wear. Replace as necessary.
- All synchronizer springs and keys for distortion or damage. Replace as necessary.
- Main shaft for grooves, scoring or unusual wear. Replace as necessary.

Measure
^ Tool Required:
- J 26900-7 Dial Caliper





- Clearance between each synchronizer ring and its respective gear using a feeler gage. Maximum synchronizer ring clearance is 1.0 to 1.4 mm (0.039 to 0.055 inch). If synchronizer ring clearance exceeds specification, replace the synchronizer ring and gear.





- Key slot width of each synchronizer ring using J 26900-7. Maximum synchronizer key slot width is 10.1 to 10.4 mm (0.397 to 0.409 inch). If synchronizer ring key slot width exceeds specification, replace the synchronizer ring.





- Clearance between each gearshift fork and its a feeler gage. Maximum gearshift fork clearance is 1.0 mm (0.039 inch). If gearshift fork clearance exceeds specification, replace the gearshift fork and synchronizer sleeve.

INSTALL OR CONNECT
^ Tools Required:
- J 37753 Bearing Installer
- J 35664 Bearing Installer
- J 28406 Bearing Installer
- J 22912-01 Split Plate
- J 35425 High Speed Hub Installer
- J 36850 Transjel(R) Transmission Assembly Lubricant








1. Low speed synchronizer springs and synchronizer keys onto low speed synchronizer hub.
2. Low speed synchronizer sleeve onto low speed synchronizer hub.
3. Apply J 36850 to the main shaft 2nd gear needle gearing.





4. Main shaft 2nd gear needle bearing, main shaft 2nd gear and low speed synchronizer ring onto main shaft.





5. Low speed sleeve and hub assembly onto main shaft using J 37753 and press arbor.





6. Main shaft 1st gear bushing onto main shaft using J 37753 and press arbor.
7. Apply J 36850 to the main shaft 1st gear needle bearing.
8. Main shaft 1st gear needle bearing, low speed synchronizer ring and main shaft 1st gear onto main shaft.





9. Main shaft washer ball and main shaft bearing washer onto main shaft.





10. Main shaft center bearing onto main shaft using J 37753 with J 35664 and press arbor.





11. Reverse synchronizer springs and three synchronizer keys to reverse synchronizer hub. The thick side of the synchronizer keys and synchronizer sleeve should face toward the main shaft 5th gear.
12. Reverse synchronizer sleeve to reverse synchronizer hub.
13. Main shaft washer ball and main shaft bearing washer to main shaft.





14. Main shaft reverse gear bushing onto main shaft using J 37753 with J 35664 and gently tapping.
15. Apply J 36850 to both halves of the main shaft reverse gear needle bearing.
16. Main shaft reverse gear needle bearing and main shaft reverse gear onto main shaft.





17. Reverse sleeve and hub assembly onto main shaft using J 37753 with J 35664 and gently tapping Into place.
18. High speed and reverse hub C-clip onto main shaft.
19. Apply J 36850 to both halves of the main shaft 5th gear needle bearing.
20. High speed synchronizer ring, main shaft 5th gear needle bearing, main shaft 5th gear, main shaft washer ball and main shaft 5th gear washer onto main shaft with oil slot in the main shaft 5th gear washer facing the main shaft 5th gear.





21. Main shaft rear bearing onto main shaft using J 22912-01 for support, J 28406 and press arbor.
22. Main shaft rear bearing C-clip onto main shaft.





23. Speedometer drive gear onto main shaft; secure with speedometer drive gear retaining rings.





24. High speed synchronizer springs and three synchronizer keys onto high speed synchronizer hub.
25. High speed synchronizer sleeve onto high speed synchronizer hub.
26. Apply J 36850 to the main shaft 3rd gear needle bearing.





27. Main shaft 3rd gear needle bearing, main shaft 3rd gear, high speed synchronizer rings and high speed sleeve and hub assembly onto main shaft using J 22912-01 for support, J 35425 and press arbor.
28. High speed and reverse hub C-clip onto main shaft.