Main Shaft Assembly
A: DISASSEMBLY1. 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.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
3. Remove 5th-Rev sleeve and hub assembly, baulk ring, 5th drive gear and needle bearing (32 x 36 x 25.7).
4. Remove snap ring and synchro cone stopper from 5th-Rev sleeve and hub assembly.
5. Using ST1, ST2 and a press, remove ball bearing, synchro cone and baulk ring (Rev).
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, mark engagement point on splines beforehand.
- Do not reuse ball bearing.
ST1 499757002 SNAP RING PRESS
ST2 498077400 SYNCHRO CONE REMOVER
6. Using ST1 and ST2, 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.
ST1 899864100 REMOVER
ST2 899714110 REMOVER
B: ASSEMBLY
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, outer baulk ring, synchro cone, inner baulk ring, sleeve and hub assembly for 3rd needle bearing on transmission main shaft.
NOTE: Align groove in baulk ring with insert key.
3. Install 4th needle bearing race onto transmission main shaft using ST1, ST2 and a press.
ST1 899714110 REMOVER
ST2 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 ST1, ST2 and a press.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
6. Using ST1 and ST2, 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.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
7. Install bearing onto synchro cone.
8. Install baulk ring and synchro cone onto 5thRev sleeve and hub assembly using ST and a press.
NOTE:
- Use new ball bearing.
- After press fitting, make sure synchro cone rotates freely.
ST 499757002 SNAP RING PRESS
9. Install synchro cone stopper and snap ring to 5th-Rev sleeve and hub assembly.
10. Install the rest parts to the rear section of transmission main shaft.
NOTE: Align groove in baulk ring with shifting insert.
ST1 499987003 SOCKET WRENCH
ST2 498937000 TRANSMISSION HOLDER
11. Tighten lock nuts to the specified torque using ST1 and ST2.
NOTE: Secure lock nuts in two places after tightening.
ST1 499987000 SOCKET WRENCH
ST2 498937000 TRANSMISSION HOLDER
Tightening torque: 118 ± 6 Nm (120 ± 0.6 kg-m, 86.8 ± 4.3 ft. lbs.)