Part 1
Gears Components: Disassembly and Assembly
Part 1
Disassembly
Gear Components
1) Remove rear extension (or OD gear case) and transmission case. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.
2) Remove shift forks and fork rods. Refer to [Transmission Assembly: Disassembly and Assembly] Transmission Disassembly and Assembly.
3) Before disassembling, measure the end play for each position. If the end play is outside the standards, disassemble and inspect.
- Main drive gear
[Service Data and Specifications] Mechanical Specifications
- Mainshaft (Rear side)
Mechanical Specifications
- Counter gear
Mechanical Specifications
4) Remove reverse idler gear according to the following.
a) Remove reverse idler shaft assembly from adapter plate.
b) Remove reverse idler thrust washer, reverse idler gear and reverse idler needle bearing from reverse idler shaft.
5) Remove reverse main gear and reverse synchronizer hub assembly according to the following.
a) Remove snap ring from mainshaft using suitable tool.
b) Remove reverse main gear and reverse synchronizer hub assembly using suitable tool.
c) Remove reverse main needle bearing from mainshaft.
6) Remove reverse coupling sleeve according to the following.
a) Remove snap ring from reverse synchronizer hub.
b) Remove spread springs and shifting inserts from reverse synchronizer hub.
c) Remove reverse coupling sleeve from reverse synchronizer hub.
7) Remove reverse counter gear according to the following.
a) Remove snap ring from counter gear using suitable tool.
b) Remove reverse counter gear using suitable tool.
8) Remove counter rear bearing spacer from counter gear.
9) Remove bearing retainer bolts, and then remove bearing retainer.
10) Remove main drive gear assembly, mainshaft assembly and counter gear assembly according to the following.
a) Remove snap ring from mainshaft bearing using suitable tool.
b) Carefully tap mainshaft using suitable tool, and then remove main drive gear assembly, mainshaft assembly and counter gear assembly from adapter plate.
c) Remove main pilot bearing, pilot bearing spacer from mainshaft.
d) Remove 5th baulk ring from main drive gear.
11) Remove counter rear bearing from adapter plate.
12) Remove magnet from adapter plate.
13) Remove baffle plate bolt, and then remove baffle plate from adapter plate.
14) Remove breather from adapter plate.
15) Remove main drive gear bearing according to the following.
a) Remove snap ring from main drive gear using suitable tool.
b) Press out main drive gear bearing using suitable tool.
16) Before disassembling, measure the end play for mainshaft (Front side). If the end play is outside the standards, disassemble and inspect.
Mechanical Specifications
17) Press out reverse main gear bushing, mainshaft bearing and 4th main gear using suitable tool.
18) Remove 3rd-4th main spacer from mainshaft.
19) Remove 3rd main gear and 1st main gear according to the following.
a) Press out 3rd main gear and 1st main gear using suitable tool.
CAUTION:
Be careful not to damage 1st outer baulk ring.
b) Remove 1st needle bearing from mainshaft.
20) Remove 1st-2nd synchronizer hub assembly and 2nd main gear according to the following.
a) Press out 1st gear bushing, 1st-2nd synchronizer hub assembly and 2nd main gear using suitable tool.
CAUTION:
Be aware that when using the press, if mainshaft gear positioner catches on the V-block, etc., mainshaft could be damaged.
b) Remove 2nd needle bearing from mainshaft.
21) Remove 1st-2nd coupling sleeve according to the following.
a) Remove spread springs and shifting inserts from 1st-2nd synchronizer hub.
b) Remove 1st-2nd coupling sleeve from 1st-2nd synchronizer hub.
22) Remove 6th main gear and 5th-6th synchronizer hub assembly according to the following.
a) Remove snap ring from mainshaft using suitable tool.
b) Press out 6th main gear and 5th-6th synchronizer hub assembly using suitable tool.
c) Remove 6th needle bearing from mainshaft.
23) Remove 5th-6th coupling sleeve according to the following.
a) Remove spread springs and shifting inserts from 5th-6th synchronizer hub.
b) Remove 5th-6th coupling sleeve from 5th-6th synchronizer hub.
24) Remove 3rd counter gear, 3rd-4th synchronizer hub assembly, 4th counter gear according to the following.
a) Press out 3rd counter gear, 3rd-4th synchronizer hub assembly, 4th counter gear, 4th needle bearing, 4th gear bushing, 4th counter gear thrust washer, and counter rear bearing inner race using suitable tool.
b) Remove 3rd needle bearing from counter gear.
25) Remove 3rd-4th coupling sleeve according to the following.
a) Remove spread springs and shifting inserts from 3rd-4th synchronizer hub.
b) Remove 3rd-4th coupling sleeve from 3rd-4th synchronizer hub.
26) Press out 3rd gear bushing using suitable tool.
CAUTION:
Do not use oil hole of 3rd gear bushing when press out.
Assembly
Gear Components
1) Install 5th-6th synchronizer hub assembly according to the following.
a) Install 5th-6th coupling sleeve to 5th-6th synchronizer hub.
CAUTION:
- Do not reuse 5th-6th synchronizer hub and 5th-6th coupling sleeve.
- Replace 5th-6th synchronizer hub and 5th-6th coupling sleeve as a set.
- Be careful with the orientation 5th-6th coupling sleeve.
- Be careful with the orientation 5th-6th synchronizer hub.
b) Install shifting inserts and spread springs to 5th-6th synchronizer hub.
CAUTION:
- Do not install spread spring hook onto the same shifting insert.
- Be careful with the shape of reserve shifting insert to avoid misemploy.
c) Press in 5th-6th synchronizer hub assembly, 6th baulk ring, 6th main gear and 6th needle bearing using Tool.
CAUTION:
- Apply gear oil to 6th baulk ring and 6th needle bearing.
- Be careful with the orientation 5th-6th coupling sleeve.
NOTE:
5th and 6th baulk rings have three spaces that four gear teeth are missing as shown.
2) Select and install a snap ring so that the end play comes within the standard value. Refer to Mechanical Specifications.
CAUTION:
Do not reuse snap ring.
3) Install 1st-2nd synchronizer hub assembly according to the following.
a) Install 1st-2nd coupling sleeve to 1st-2nd synchronizer hub.
CAUTION:
- Do not reuse 1st-2nd coupling sleeve and 1st-2nd synchronizer hub.
- Replace 1st-2nd synchronizer hub and 1st-2nd coupling sleeve as a set.
- Be careful with the orientation 1st-2nd coupling sleeve.
- Be careful with the orientation 1st-2nd synchronizer hub.
b) Install spread springs and shifting inserts to 1st-2nd synchronizer hub.
CAUTION:
- Do not install spread spring hook onto the same shifting insert.
- Be careful with the shape of reverse shifting insert to avoid misassembly.
c) Press in 1st-2nd synchronizer hub assembly, 2nd inner baulk ring, 2nd synchronizer cone and 2nd outer baulk ring, 2nd main gear and 2nd needle bearing using Tool.
CAUTION:
- Apply gear oil to 2nd needle bearing, 2nd inner baulk ring, 2nd synchronizer cone and 2nd outer baulk ring, 1st-2nd synchronizer hub spline of mainshaft.
- Replace 2nd inner baulk ring, 2nd synchronizer cone and 2nd outer baulk ring as a set.
- Be careful with the orientation 1st-2nd coupling sleeve.
NOTE:
1st outer baulk ring has three spaces that three gear tooth is missing and 2nd outer baulk ring has three spaces that two gear teeth are missing.
4) Press in 1st gear bushing using Tool.
5) Install 1st outer baulk ring, 1st synchronizer cone, 1st inner baulk ring, 1st needle bearing and 1st main gear to mainshaft.
CAUTION:
- Apply gear oil to 1st outer baulk ring, 1st synchronizer cone, 1st inner baulk ring and 1st needle bearing.
- Replace 1st outer baulk ring, 1st synchronizer cone and 1st inner baulk ring as a set.
NOTE:
1st outer baulk ring has three spaces that three gear tooth is missing and 2nd outer baulk ring has three spaces that two gear teeth are missing.
6) Press in 3rd main gear using Tool.
CAUTION:
- Do not reuse 3rd main gear.
- Be careful with the orientation 3rd main gear.
7) Install 3rd-4th main spacer to mainshaft.
