Main Shaft

MAIN SHAFT








COMPONENTS

DISASSEMBLY

NOTE: Use care to prevent the main shaft from falling when pressing fears and assemblies from it.





1. Remove 4th gear sleeve snap ring.





2. Using SST (09432-3E000), remove 3rd & 4th synchronizer hub, sleeve, 3rd speed gear and synchronizer ring (3rd).
3. Remove 3rd speed gear needle bearing.





4. Using SST (09432-3E600), remove 2nd gear and 3rd speed gear bearing sleeve.
5. Remove synchronizer ring (2ND).





6. Using SST (09432-3E100), remove 1st & 2nd synchronizer hub and sleeve and 1st gear after removing snap ring.
7. Remove synchronizer ring (1st).
8. Remove 1st speed gear needle bearing.





9. Using SST (09432-3E200), remove main shaft rear ball bearing after removing snap ring.





10. Using SST (09432-H1100/09432-3E300), remove lock nut after releasing caulking of lock nut.





11. Using SST (09432-3E400), remove space after removing double bearing.
12. Remove 5th speed gear, synchronizer ring (5th) and 5th speed gear needle bearing.





13. Using SST (09432-3E000), remove 5th&R synchronizer sleeve and hub and reverse gear.
14. Remove synchronizer ring (Reverse).

ASSEMBLY

NOTE: Clean perfectly every part before assembly.





1. Install reverse needle bearing onto the main shaft.

NOTE: Apply grease to reverse needle bearing.





2. Install reverse gear and synchronizer ring (Reverse).

NOTE: Check and separate synchronizer ring of each gear before assembly as shown.





3. Using SST (OK552 171 AAO), install 5th&R sleeve hub assembly.





4. Install snap ring.





5. Measure the clearance between sleeve hub and snap ring with feeler gage after installing snap ring.
End play: 0.0 - 0.08 mm (0 - 0.0031 inch)





6. Install 5th needle bearing and 5th synchronizer ring (Single cone).

NOTE: Apply transmission oil to needle bearing.





7. Insert ball as shown after installing 5th gear.





8. Install space with suitable tool after applying transmission oil to space.





9. Install the double bearing using SST (09432-3A100) after install double bearing support bracket with flat face up.





10. Tighten hub lock nut.
Tightening torque: 170 - 190 Nm (1700 - 1900 kg-cm, 120 - 140 ft. lbs.)





11. Calk one part of lock nut using suitable tool.





12. Install snap ring under the rear ball bearing of main shaft.





13. Using SST (09432-22000), install the rear ball bearing of main shaft, then install snap ring at the upper end of rear ball bearing.





14. Rotate main shaft to reverse direction and install 1st needle bearing.

NOTE: Apply transmission oil to 1st needle bearing.





15. Install 1st gear and synchronizer ring (1st).





16. Using SST (OK552 171 MO), install 1st & 2nd synchronizer sleeve and hub.

NOTE: Align hub groove and synchronizer ring groove in the side face as shown when pressing.





17. Install snap ring.





18. Measure the clearance between sleeve and snap ring using feeler gage after installing 1st & 2nd sleeve and snap ring.
End play: 0.0 - 0.08 mm (0 - 0.0031 inch)





19. Install 2nd needle bearing and synchronizer ring (2nd).

NOTE: Apply transmission oil to 2nd needle bearing.





20. Install 2nd gear snap ring after installing snap ring guide. (09432-3E800)





21. Install 2nd gear onto the main shaft.





22. Using SST (09432-22000), install 3rd speed gear bearing sleeve.





23. Measure the clearance between 2nd gear and main shaft sleeve using feeler gage.
End play: 0.13 - 0.28 mm (0.0051 - 0.0110 inch)





24. Install 3rd needle bearing.

NOTE: Apply transmission oil to 3rd needle bearing.





25. Install 3rd gear onto the main shaft.
End play: 0.1 - 0.2 mm (0.0039 - 0.0079 inch)





26. Install 3rd synchronizer ring (3rd).





27. Using SST (OK9A1 190 004), install 3rd & 4th synchronizer sleeve and hub.





28. Measure the clearance between sleeve and snap ring using feeler gage after installing snap ring.
End play: 0.0 - 0.08 mm (0 - 0.0031 inch)





29. Install 4th synchronizer ring (4th).





30. Install 4th needle bearing.

NOTE: Apply transmission oil to 4th needle bearing.





31. Install main drive pinion gear onto the main shaft.





32. Measure the clearance of 1st and reverse gear.
End play:
1st: 0.10 - 0.20 mm (0.0039 - 0.0079 inch)
R: 0.08 - 0.18 mm (0.0031 - 0.0071 inch)





33. Measure the clearance of 2nd and 3rd gear.
End play:
2nd: 0.1 - 0.25 mm (0.0039 - 0.0098 inch)
3rd: 0.1 - 0.2 mm (0.0039 - 0.0079 inch)





34. Measure the clearance of 5th gear.
End play: 0.13 - 0.28 mm (0.0051 - 0.0110 inch)





35. Measure the length of main shaft.