Mainshaft Disassembly/Inspection/Reassembly

Disassembly





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





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

Inspection





1. Inspect the gear surface and bearing surface for wear and damage, the 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.
Standard:
A (Ball bearing surface): 27.987 - 28.000 mm (1.1018 - 1.1024 inch)
B (Needle bearing surface): 37.984 - 38.000 mm (1.4954 - 1.4961 inch)
C (Ball bearing surface): 27.977 - 27.990 mm (1.1015 - 1.1020 inch)
Service Limit:
A: 27.940 mm (1.1000 inch)
B: 37.930 mm (1.4933 inch)
C: 27.940 mm (1.1000 inch)





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.
Standard: 0.02 mm (0.001 inch) max.
Service Limit: 0.05 mm (0.002 inch)

Reassembly

Special Tools Required
- Driver, 40 mm I.D. 07746-0030100
- Attachment, 35 mm I.D. 07746-0030400
- Driver 07749-0010000
- Attachment, 42 x 47 mm 07746-0010300

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 3rd gear, its bearing, and the 3rd gear synchro ring and synchro spring on the shaft.





3. Support 2nd gear (A) on steel blocks, then install the 3rd/4th synchro hub (B) using the special tools and a press (C). Note the direction of installation for the 3rd/4th synchro hub. After installing, check the operation of the 3rd/4th synchro hub set.
4. Install the 4th gear synchro spring and ring, 4th gear and its bearing, the spacer ring, and 5th gear and its bearing on the shaft.





5. Install the 5th synchro hub (A) using the special tools and a press (B).
6. Install the spacer and tapered cone ring.





7. Install the angular ball bearing (A) with the thin edged outer race facing down. Use the special tools and a press (B).