With FS5R30A Transmission

Case Components




1. Remove check ball plug, check spring and check ball. Then remove interlock stopper.
If interlock assembly is removed as a unit, the check ball can fall into transmission case.




2. Remove control housing, return spring and check ball.




3. Drive out retaining pin from striking arm.




4. Remove rear extension (or O.D. gear case) together with striking arm by tapping lightly.




5. Remove front cover and gasket.




6. Remove stopper ring and main drive bearing snap ring.




7. Remove transmission case by tapping lightly.




8. Remove front cover oil seal.

Shift Control Components




1. Mount adapter plate on vise.
2. Remove O.D. & reverse fork rod.




3. Drive out retaining pin from striking lever.
4. While pulling out striking rod, remove striking lever and striking interlock. Then remove 1st & 2nd, 3rd & 4th and reverse shift fork.




5. Drive out retaining pin from O.D. shift fork.
6. Pull out O.D. fork rod and then remove O.D. shift fork.

Gear Components







1. Before removing gears and shafts, measure each gear end play.
- If not within specification, disassemble and check contact surface of gear to hub, washer, bushing, needle bearing and shaft.




2. Remove rear side components on mainshaft and counter gear.
a. Remove reverse coupling sleeve.




b. Remove mainshaft rear snap ring and counter gear rear snap ring.
c. Remove O-ring holder and mainshaft O-rings from mainshaft. Use punch and hammer to remove O-rings.




d. Pull out counter gear rear end bearing.
e. Remove reverse idler gear and reverse idler thrust washers.




f. Pull out mainshaft rear bearing (2WD model).




g. Pull out reverse main gear together with mainshaft spacer and reverse synchronizer hub. Then remove reverse gear needle bearings.




h. Pull out reverse counter gear.
i. Remove O.D. coupling sleeve together with O.D. baulk ring, reverse baulk ring and spring inserts.




j. Pull out reverse gear bushing.




k. Pull out O.D. counter gear together with reverse cone.




3. Press out mainshaft and counter gear alternately.




4. Remove front side components on mainshaft.
a. Remove 1st gear washer and steel ball.
b. Remove 1st main gear and 1st gear needle bearing.




c. Press out 2nd main gear together with 1st gear bushing and 1st & 2nd synchronizer assembly.
d. Remove mainshaft front snap ring.




e. Press out 3rd main gear together with 3rd & 4th synchronizer assembly and 3rd gear needle bearing.




5. Remove front side components on counter gear.
a. Remove counter gear rear thrust bearing.




b. Remove sub gear components.




6. Remove main drive gear bearing.
a. Remove main drive gear snap ring and spacer.
b. Press out main drive gear bearing.




7. Remove bearings from case components.