Disassembly

GEAR COMPONENTS


Disassembly


GEAR COMPONENTS
1. Remove OD gear case and transmission case. Disassembly.
2. Remove shift forks and fork rods. Disassembly.
3. Before disassembling, measure the end play for each position. If the end play is outside the standards, disassemble and inspect.





- Main drive gear










- Mainshaft (Rear side)










- Counter gear






4. Remove revers idler gear according to the following.





a. Remove reverse idler shaft assembly from adapter plate.
b. Remove reverse idler thrust washer, revers idler gear and reverse idler needle bearing from reverse idler shaft.
5. Remove reverse main gear and reverse synchronizer hub assembly according to the following.





a. Remove snap ring from mainshaft using suitable tool.





b. Remove reverse main gear and reverse synchronizer hub assembly using suitable tool.
c. Remove reverse main needle bearing from mainshaft.
6. Remove reverse coupling sleeve according to the following.





a. Remove snap ring from reverse synchronizer hub.
b. Remove spread springs and shifting inserts from reverse synchronizer hub.
c. Remove reverse coupling sleeve from reverse synchronizer hub.
7. Remove reverse counter gear according to the following.





a. Remove snap ring from counter gear using suitable tool.





b. Remove reverse counter gear using suitable tool.
8. Remove counter rear bearing spacer from counter gear.





9. Remove bearing retainer bolts, and then remove bearing retainer.
10. Remove main drive gear assembly, mainshaft assembly and counter gear assembly according to the following.





a. Remove snap ring from mainshaft bearing using suitable tool.





b. Carefully tap mainshaft using suitable tool, and then remove main drive gear assembly, mainshaft assembly and counter gear assembly from adapter plate.
c. Remove main pilot bearing, pilot bearing spacer from mainshaft.
d. Remove 5th baulk ring from main drive gear.





11. Remove counter rear bearing from adapter plate.





12. Remove magnet from adapter plate.





13. Remove baffle plate bolt, and then remove baffle plate from adapter plate.





14. Remove breather from adapter plate.
15. Remove main drive gear bearing according to the following.





a. Remove snap ring from main drive gear using suitable tool.





b. Press out main drive gear bearing using suitable tool.





16. Before disassembling, measure the end play for mainshaft
(Front side). If the end play is outside the standards, disassemble and inspect.










17. Press out reverse main gear bushing, mainshaft bearing and 4th main gear using suitable tool.
18. Remove 3rd-4th main spacer from mainshaft.
19. Remove 3rd main gear and 1st main gear according to the following.





a. Press out 3rd main gear and 1st main gear using suitable tool.

CAUTION:
Be careful not to damage 1st outer baulk ring.
b. Remove 1st needle bearing from mainshaft.
20. Remove 1st-2nd synchronizer hub assembly and 2nd main gear according to the following.





a. Press out 1st gear bushing, 1st-2nd synchronizer hub assembly and 2nd main gear using suitable tool.

CAUTION:
Be aware that when using the press, if mainshaft gear positioner catches on the V-block, etc., mainshaft could be damaged.
b. Remove 2nd needle bearing from mainshaft.
21. Remove 1st-2nd coupling sleeve according to the following.
a. Remove spread springs and shifting inserts from 1st-2nd synchronizer hub.
b. Remove 1st-2nd coupling sleeve from 1st-2nd synchronizer hub.
22. Remove 6th main gear and 5th-6th synchronizer hub assembly according to the following.





a. Remove snap ring from mainshaft using suitable tool.





b. Press out 6th main gear and 5th-6th synchronizer hub assembly using suitable tool.
c. Remove 6th needle bearing from mainshaft.
23. Remove 5th-6th coupling sleeve according to the following.
a. Remove spread springs and shifting inserts from 5th-6th synchronizer hub.
b. Remove 5th-6th coupling sleeve from 5th-6th synchronizer hub.
24. Remove 3rd counter gear, 3rd-4th synchronizer hub assembly, 4th counter gear according to the following.





a. Press out 3rd counter gear, 3rd-4th synchronizer hub assembly, 4th counter gear, 4th needle bearing, 4th gear bushing, 4th counter gear thrust washer, and counter rear bearing inner race using suitable tool.
b. Remove 3rd needle bearing from counter gear.
25. Remove 3rd-4th coupling sleeve according to the following.
a. Remove spread springs and shifting inserts from 3rd-4th synchronizer hub.
b. Remove 3rd-4th coupling sleeve from 3rd-4th synchronizer hub.





26. Press out 3rd gear bushing using suitable tool.

CAUTION:
Do not use oil hole of 3rd gear bushing when press out.