Disassembling Gear Carrier

Exploded View:

Description:

Disassembling

1. Remove end cover by puncturing center of rubber with a large screwdriver and prying off cover.

2. Clamp input shaft in a vise and unscrew input shaft bolt. Fit vise with soft jaws!

3. Clamp gear carrier in vise and unscrew rear cover mounting bolts.

4. Drive off rear cover with a plastic hammer and remove 1st inner race/ball bearing (A).

5. Pull off clutch body and 2nd inner race/ball bearing.
A - Two-arm puller (standard), e.g. Kukko 20/10

6. Remove 5th gear synchromesh ring.

7. Drive out 5th gear selector fork dowel sleeve. Hold with a hammer so that selector rod bore in end bracket is not widened.

8. Remove circlip for synchronizer.

9. Remove 5th gear with sliding sleeve and synchronizer. needle bearing and 5th gear selector fork. Selector rod remains in gear carrier!

10. Unscrew stop bolts for selector rods.

11. Clamp 4th gear/drive pinion in a vise and unscrew bolt for drive pinion. Make sure vise is fitted with soft jaws!

12. Pull off 5th gear.
A - Two-arm puller (standard) e.g. Kukko 20/10, if necessary grind off claws slightly or pry away gear slightly with two tire irons.

13. Remove shim for 5th gear.

14. Clamp gear carrier with shafts forward in vise.

15. Drive out dowel sleeve for dog on 1st and 2nd gear selector rod, while holding with a hammer. Turn dog to face up.

16. Drive out dowel sleeve for 3rd and 4th gear selector fork, while holding with a hammer.

17. Pull out selector rod for 3rd and 4th gears (selector fork remains in sliding sleeve). Do not loose small lock pin!

18. Unscrew bolt for operating lever.

19. Pull drive pinion and input shaft forward slightly. Remove input shaft with 3rd and 4th gear selector fork.

Note: For transmissions with reverse gear synchronization disconnect spring clamp for reverse gear on pinion shaft end and turn aside.

20. Pull drive pinion forward far enough so that selector rod.and selector fork for 1st and 2nd gears can be removed.

21. Swing out drive pinion.