d. Mainshaft Disassemble

- Tools Required
- J 22912-01 Bearing and Gear Puller

Important: The synchronizer hubs and the sliding sleeves are a selected assembly. Keep these parts together as originally assembled. Replace worn or broken keys and springs.





1. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.





2. Remove the following parts:
2.1. The 4th speed gear blocking ring
2.2. The 3rd/4th speed gear synchronizer
2.3. The 3rd speed gear blocker ring
3. Remove the 3rd speed gear using the J 22912-01 and a hydraulic press.





4. Remove the 3rd speed gear needle bearing assembly and the spacer.





5. Remove the 2nd speed gear retainer ring.





6. Remove the thrust washer and the 2nd speed gear.





7. Remove the 2nd speed gear needle bearing assembly and the spacer.





8. Remove the synchronizer spiral retaining ring.





9. Remove the following parts:
9.1. The 1st speed gear thrust washer
9.2. The 1st/2nd speed gear synchronizer inner cone
9.3. The 1st/2nd speed gear synchronizer outer cone
9.4. The 1st/2nd speed gear synchronizer blocking ring





10 Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.
11. Remove the 1st/2nd speed synchronizer spring and the inserts from the reverse sliding gear.





12. Remove the reverse sliding gear.





13. Remove 5th speed driven gear. Using the J22912-01 and a hydraulic press.





14. Remove the mainshaft rear bearing assembly.





15. Remove the 1st speed gear.





16. Remove the following parts in order:
16.1. The 1st speed gear needle bearing assembly
16.2. The bearing sleeve ball
16.3. The bearing sleeve ball (5 mm diameter)





17. Remove the following parts in order:
17.1. The 1st speed gear synchronizer outer cone
17.2. The 1st speed gear synchronizer inner cone
17.3. The 1st speed gear synchronizer blocking ring