Five Speed

DISASSEMBLY




MAJOR COMPONENT

Important operation




5. Believille spring
Remove the bearing retainer and the retainer, gasket and belleville spring.

Main Shaft Assembly, Cluster Gear Assembly And Top Gear Assembly:

MINOR COMPONENTS

Disassembly steps
1. Plate detent spring
2. Spring ; detent ball
3. Ball; detent, gear shift
4. Shaft; arm, gear shift, reverse-5th *
5. Fork; reverse-5th, shift
6. Shaft; gear shift low-2nd *
7. Shaft; gear shift, top-3rd
8. Fork ; top-3rd, shift
9. Fork; low-2nd, shift
10. Pin and plug ; inter lock
11. Ring ; snap, speed drive gear
12. Gear; speed, drive
13. Key; feather, speed drive gear
14. Spacer; bearing, drive gear
15. Bearing ; ball, main shaft end
16. Ring ; snap, ball bearing
17. Ring ; snap, thrust ring
18. Retaining ring
19. Thrust ring ; 5th gear
20. Washer; thrust, 5th
21. Nut; self lock, counter
22. Washer ; plain, counter 5th gear
23. Bearing ; ball, counter end *
24. Gear; counter, 5th *
25. Gear assembly; 5th with synchronizer cone
26. Bearing ; needle, 5th
27. Ring ; block, 5th
28. Nut; main shaft *
29. Washer; lock, main shaft
30. Synchronizer assembly; reverse-5th
31. Gear; reverse, main shaft
32. Bearing ; needle, low
33. Nut; self lock, counter
34. Washer; thrust, reverse idle, rear
35. Gear; reverse idle, with bushing
36. Washer; thrust, reverse idle, front
37. Plate; intermediate
38. Ring ; snap, bearing to top shaft
39. Shaft; top gear, with synchronizer cone
40. Bearing ; ball, top gear shaft *
41. Bearing ; needle, main shaft
42. Ring; block, top-3rd
43. Ring ; snap, main shaft
44. Synchronizer assembly; top-3rd
45. Ring ; block, top-3rd
46. Gear assembly; 3rd with synchronizer cone
47. Bearing ; needle, 2nd, 3rd
48. Gear assembly; low-2nd *
49. Washer thrust, low
50. Bearing ; radial ball, main shaft *
51. Collar ; needle bearing, low
52. Washer; thrust, low
53. Gear assembly low, with synchronizer cone
54. Bearing ; needle, low
55. Collar ; needle bearing, low
56. Ring ; block, low-2nd
57. Synchronizer assembly ; low-2nd
58. Ring ; block, low-2nd
59. Gear assembly ; 2nd with synchronizer cone
60. Bearing ; needle, 2nd, 3rd
61. Gear; counter reverse *
62. Bearing ; angular ball, cluster *
63. Gear; cluster
64. Ring ; snap, cluster gear
65. Bearing ; ball, counter front
66. Ring ; snap, cluster gear
67. Ring ; snap, main shaft
68. Shift ; reverse idle

* Important operations

Important operations




4. Shaft ; arm, gearshift reverse-5th
Remove the spring pin with suitable tools, then pull out the shift rod.

NOTE: Discard the used spring pin.

6. Shift ; arm, gear shift, low-2nd




7. Shift ; arm, gear shift, top-3rd
When removing the spring, hold a round bar against the end of the shift rod for protection against damage.

23. Bearing ; ball, counter end




24. Gear ; counter, 5th

Remover : J-22888

28. Nut ; main shaft




1. Engage top/3rd synchronizer with the third gear and Low/2nd side synchronizer with the Low gear, then attach Tool J-29768 to the main shaft and the countergear.




2. This operation is necessary to prevent turning of the shaft when removing main shaft rear and countershaft reverse gear lock nut.

Wrench : J-33441




40. Bearing ; ball, top gear shaft
Use a bench press

Remover : J-22912-01




48. Gear assembly ; low-2nd
Remove the parts (47 through 58) from the main shaft together using special tool.

Remover : J-22912-01




50. Bearing ; radial ball, main shaft
Use a bench press.

Remover : J-22912-01

61. Gear ; counter reverse




62. Bearing ; angular ball, cluster
Use a bench press for removal.

Remover : J-22912-01