Part 2

MAINSHAFT AND GEARS
DISASSEMBLY








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

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 with Tool.





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.

INSPECTION
GEAR AND SHAFT
- Check shaft for cracks, wear and bending.





- Check gears for excessive wear, chips and cracks.

SYNCHRONIZER





- Check spline portion of coupling sleeves, hubs and gears for wear and cracks.
- Check baulk rings for cracks and deformation.
- Check insert springs for deformation.








- Measure clearance between baulk ring and gear (1st).





- Measure wear of 2nd baulk rings.
a. Place baulk rings in position on synchronizer cone.
b. While holding baulk ring against synchronizer cone as far as it will go, measure dimensions "A" and "B".





c. If dimension "A" or "B" is smaller than the wear limit, replace baulk ring.