Mainshaft and Gears

DISASSEMBLY





1. Before disassembly, check 1st and 2nd main gear end plays.
Gear end play: Refer to Specifications.
- 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 wear of 1st and 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".
Standard and wear limit: Refer to Specifications.
c. If dimension "A" or "B" is smaller than the wear limit, replace outer baulk ring, inner baulk ring and synchronizer cone as a set.

Bearing





- Make sure bearings roll freely and are free from noise, cracks, pitting and wear.
- When replacing tapered roller bearing, replace outer and inner race as a set.





ASSEMBLY





1. Press on 1st main gear, 1st synchronizer cone, inner and outer baulk rings and 1st & 2nd synchronizer hub.
- 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 inch)
Snap ring of 1st & 2nd synchronizer hub: Refer to Specifications.





3. Install 2nd synchronizer cone, inner & outer baulk rings. Insert springs and 1st & 2nd coupling sleeve.
4. Install 2nd main gear.
- Ensure four protrusions of 2nd synchronizer cone are set in 2nd main gear holes.





5. Use Tool to press on 3rd main gear.
6. Use Tool to press on 4th main gear.





7. Use Tool to 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 inch)
Snap ring of 5th main gear: Refer to Specifications.





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. Refer to "DISASSEMBLY".