Mainshaft Assembly
A: DISASSEMBLY1. 2200 cc Model
1. Put vinyl tape around main shaft splines to protect oil seal from damage. Then pull out oil seal and needle bearing by hand.
2. Remove lock nut from transmission main shaft assembly.
NOTE: Remove caulking before taking off lock nut.
Special Service Tool(SST)1 498937000 TRANSMISSION HOLDER
(SST)2 499987003 SOCKET WRENCH (35)
3. Remove insert stopper plate, sleeve and hub assembly No. 2, baulk ring, 5th drive gear, and needle bearing.
4. Using SST1 and SST2, remove the rest of parts.
NOTE: Replace sleeve and hub with new ones. Do not attempt to disassemble because they must engage at a specified point. If they should be disassembled, marking engagement point on splines beforehand.
SST1 899864100 REMOVER
SST2 899714110 REMOVER
B: ASSEMBLY
1. 2200 cc Model
1. Assemble sleeve and hub assembly for 3rd-4th and, 5th synchronizing.
NOTE: Position open ends of spring 120° apart.
2. Install 3rd drive gear, baulk ring, and sleeve and hub assembly for 3rd-4th needle bearing (32 x 36 x 25.7) on transmission main shaft.
NOTE: Align groove in baulk ring with shifting insert.
3. Install 4th needle bearing race onto transmission main shaft using SST1, SST2 and a press.
SST1 899714110 REMOVER
SST2 499877000 RACE 4-5 INSTALLER
4. Install baulk ring, needle bearing (32 x 30 x 25.7), 4th drive gear and 4th gear thrust washer to transmission main shaft.
5. Drive ball bearing onto the rear section of transmission main shaft using SST1, SST2 and a press.
SST1 899714110 REMOVER
SST2 499877000 RACE 4-5 INSTALLER
6. Using SST1 and SST2, install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft.
NOTE: Face thrust washer in the correct direction.
SST1 899714110 REMOVER
SST2 499877000 RACE 4-5 INSTALLER
7. Install the following parts to the rear section of transmission main shaft.
NOTE:
- Align groove in baulk ring with shifting insert.
- Be sure to fit pawl of insert stopper plate into 4 mm (0.16 inch) dia. hole in the boss section of synchronizer hub.
8. Tighten lock nuts (22 x 13) to the specified torque using SST1 and SST2.
NOTE: Secure lock nuts in two places after tightening.
SST1 499987003 SOCKET WRENCH (35)
SST2 498937000 TRANSMISSION HOLDER
Tightening torque
118 ± 6 Nm (12.0 ± 0.6 kg-m, 86.8 ± 4.3 ft. lbs.)