Part 1 of 2
Main Shaft AssemblyREMOVAL
1) Remove the manual transmission assembly from vehicle.
2) Remove the transfer case with extension case assembly.
3) Remove the transmission case.
4) Remove the drive pinion shaft assembly.
5) Remove the main shaft assembly.
INSTALLATION
1) Install the needle bearing and oil seal onto the front of transmission main shaft assembly.
NOTE:
^ Wrap the clutch splined section with vinyl tape to prevent damage to oil seal.
^ Apply Unilube #2 or equivalent to the sealing lip of oil seal.
^ Use anew one.
2) Install the transmission case knock pin into needle bearing outer race knock pin hole.
NOTE:
Align the end face of seal with surface (A) when installing oil seal.
3) Install the drive pinion shaft assembly.
4) Install the transmission case.
5) Install the transfer case with extension case assembly.
6) Install the manual transmission assembly to vehicle.
DISASSEMBLY
1) Put vinyl tape around the main shaft splines to protect oil seal from damage. Then pull out the oil seal and needle bearing by hand.
2) Remove the lock nut from transmission main shaft assembly.
NOTE:
Remove the caulking before removing lock nut.
ST1 498937000 TRANSMISSION HOLDER
ST2 499987003 SOCKET WRENCH (35)
3) Remove the 5th-Rev sleeve & hub assembly, baulk ring, 5th drive gear and needle bearing.
4) Remove the snap ring and synchro cone stopper from 5th-Rev sleeve & hub assembly.
5) Using the ST1, ST2 and a press, remove the ball bearing, synchro cone and baulk ring (Rev).
NOTE:
^ Replace the 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 the ball bearing.
ST1 499757002 INSTALLER
ST2 498077400 SYNCHRO CONE REMOVER
6) Using the ST1 and ST2, remove rest of the parts.
NOTE:
Replace the 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.
ST1 899864100 REMOVER
ST2 899714110 REMOVER
