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 snap ring, speedometer drive gear and steel ball.
b. Remove reverse coupling sleeve.




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




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




g. Remove sub-gear from reverse idler gear.




h. Pull out mainshaft rear bearing.




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




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




l. Pull out reverse gear bushing.




m. 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.