Disassembly and Assembly

Disassembly




1. Before disassembly, check 1st and 2nd main gear end plays.

Gear End Play: Service Data and Specifications (SDS)

Note: If not within specification, disassemble and check contact surface of gear, shaft and hub. Then check clearance of snap ring groove. Refer to "ASSEMBLY".




2. Press out mainshaft rear bearing with tool.




3. Remove thrust washer and snap ring.




4. Press out 5th main gear and 4th main gear.




5. Press out 3rd main gear and 2nd main gear with tool.




6. Remove snap ring.




7. Remove 1st & 2nd synchronizer and 1st main gear.




8. Remove mainshaft front bearing with Tool.

Assembly










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

Note: Pay attention to direction of 1st & 2nd synchronizer hub.

2. Select proper snap ring of 1st & 2nd synchronizer hub to minimize clearance of groove and then install it.

Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in)
Snap ring of 1st & 2nd synchronizer hub:Service Data and Specifications (SDS)




3. Install 2nd synchronizer cone, inner & outer baulk rings. Insert springs and 1st & 2nd coupling sleeve.
4. Install 2nd main gear.

Note: Ensure four protrusions of 2nd synchronizer cone are set in 2nd main gear holes.




5. Press on 3rd main gear.
6. Press on 4th main gear.




7. Press on 5th main gear.
8. Select proper snap ring of 5th main gear to minimize clearance of groove and then install it.

Allowable clearance of groove: 0 - 0.15 mm (0 - 0.0059 in)
Snap ring of 5th main gear: Service Data and Specifications (SDS)




9. Press on thrust washer and press on mainshaft rear bearing.




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