Disassembly and Assembly

DISASSEMBLY




1. Before disassembly, measure gear end play.

Gear end play:
1st main gear 0.18 - 0.31 mm (0.0071 - 0.0122 in)
2nd - 4th main gear 0.20 - 0.30 mm (0.0079 - 0.0118 in)

- If end play is not within the specified limit, disassemble and check the parts.







2. Remove mainshaft rear bearing snap ring, C-ring holder and C-rings.




3. Remove mainshaft bearing and spacer.




4. Remove 5th main gear with tool.




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

Note: Take care not to lose steel ball.




6. Remove 3rd & 4th synchronizer and 3rd main gear with tool.




7. Remove 2nd & 3rd bushing and 2nd main gear.

Note: Take care not to lose the steel ball.




8. Remove 1st & 2nd synchronizer hub and 1st main gear.

ASSEMBLY




1. Install 1st gear needle bearing, 1st main gear and baulk ring.
2. Press on 1st & 2nd synchronizer hub.




- Ensure correct fitting of 1st & 2nd synchronizer hub.




3. Install 2nd synchronizer cone, outer & inner baulk ring and 1st & 2nd coupling sleeve.




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

Note: Apply gear oil to 2nd & 3rd bushing before installing it.

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




5. Install 3rd main gear, synchronizer cone, outer & inner baulk ring.
6. Press on 3rd & 4th synchronizer hub.




- Ensure correct fitting of 3rd & 4th synchronizer hub.
7. Install 3rd & 4th coupling sleeve and 4th baulk ring.




8. 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.




9. Press on 5th main gear.

Spacers Available:

10. Select proper mainshaft bearing spacer to give correct bearing distance.

Bearing distance "C":
230.15 230.25 mm (9.0610 - 9.0649 in)




11. Press on mainshaft rear bearing with tool.

Mainshaft C-rings:

12. Select proper C-ring to minimize clearance of groove in mainshaft and install it.

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




13. Install C-ring holder and snap ring.
14. Measure gear end play as the final check - Refer to "Disassembly" above.