Disassembly and Assembly

DISASSEMBLY

Gear End Play:

1. Before disassembly, check 1st, 2nd, 3rd and 4th main gear end plays.

Note: If not within specification, disassemble and check contact surface of gear, shaft and hub. Then check clearance of C-ring groove.





2. Press out mainshaft front bearing.




3. Press Out mainshaft rear bearing.




4. Remove C-rings, C-ring holder and thrust washer.




5. Press out 5th main gear.




6. Remove 4th main gear, 4th bushing and steel ball.

Note: Be careful not to lose steel ball.




7. Remove 3rd & 4th synchronizer, 3rd main gear, 2nd & 3rd bushing, steel ball and 2nd main gear.

Note: Be careful not to lose steel ball.




8. Remove 1st & 2nd synchronizer and 1st main gear, then remove 1st gear needle bearing.

ASSEMBLY




1. Assemble 1st & 2nd and 3rd & 4th synchronizers.




Note: Be careful not to hook front and rear ends of spread spring to the same insert.




2. Install 1st gear needle bearing and 1st main gear.
3. Press on 1st & 2nd synchronizer.




4. Install steel ball, 2nd main gear, 2nd & 3rd bushing, 3rd main gear and 3rd & 4th synchronizer.

Note: Apply multi-purpose grease to steel ball before installing it. 2nd & 3rd bushing has a groove in which steel ball fits.




5. Install steel ball, 4th bushing and 4th main gear.

Note: Apply multi-purpose grease to steel ball before installing it. 4th bushing has a groove in which steel ball fits.




6. Press on 5th main gear.




7. Install thrust washer.

Mainshaft C-ring:

8. Select proper C-ring to minimize clearance of groove in main- shaft and install it.

Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in)

9. Install C-ring holder.




10. Press on mainshaft rear bearing




11. Press on mainshaft front bearing.
12. Measure gear end play as the final check.