Disassembly and Assembly

DISASSEMBLY




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

Gear end play: [1][2]Mechanical Specifications

- If not within specification, disassemble and check contact surface of gear, shaft and hub. Then check clearance of C-ring groove - Refer to "Assembly" below.




2. Press out mainshaft front and rear bearing with tool.




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




4. Press out 5th main gear with tool.




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

Note: Be careful not to lose steel ball.




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

Note: Be careful not to lose steel ball.




7. 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 with tool.

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.
8. 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)
Mainshaft C-ring: [1][2]Mechanical Specifications


9. Install C-ring holder.




10. Press on mainshaft rear bearing with tool.




11. Press on mainshaft front bearing.
12. Measure gear end play as the final check - Refer to "Disassembly" above.