Gear Components

DISASSEMBLY





1. Before removing gears and shafts, measure each gear end play.
Gear end play: Refer to Specifications; Mechanical.
- 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 C-ring holder and mainshaft C-rings from mainshaft. Use punch and hammer to remove C-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 OD coupling sleeve together with OD baulk ring, reverse baulk ring and spring inserts.





j. Pull out reverse gear bushing.





k. Pull out OD 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.
- Be careful not to lose steel ball.





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.
b. Press out main drive gear bearing.





7. Remove bearings from case components.