DISASSEMBLY AND REASSEMBLY



Disassembly steps

>>M<<
 1.
 Snap ring
<<A>>
 >>L<<
 2.
 Ball bearing


3.
 Input collar

>>K<<
 4.
 Synchronizer sleeve
<<B>>
 >>J<<
 5.
 5th speed-reverse synchronizer hub


6.
 Synchronizer lever


7.
 Synchronizer ring


8.
 5th speed gear


9.
 Needle roller bearing
<<C>>
 >>I<<
 10.
 5th speed gear sleeve


11.
 4th speed gear


12.
 Needle roller bearing
<<D>>
 >>H<<
 13.
 4th speed gear sleeve

>>E<<
 14.
 Synchronizer ring

>>D<<
 15.
 Synchronizer spring

>>G<<
 16.
 Synchronizer sleeve

>>F<<
 17.
 3rd-4th speed synchronizer hub

>>E<<
 18.
 Synchronizer ring

>>D<<
 19.
 Synchronizer spring


20.
 3rd speed gear


21.
 Needle roller bearing

>>C<<
 22.
 Snap ring
<<E>>
 >>B<<
 23.
 Ball bearing

>>A<<
 24.
 Oil seal


25.
 Input shaft

DISASSEMBLY SERVICE POINTS

<<A>> BALL BEARING REMOVAL

1.Using special tool Bearing remover (MD998801), support the ball bearing, and then set them on the press.
2.Push down on the input shaft with the press and remove the ball bearing.

<<B>> 5TH SPEED-REVERSE SYNCHRONIZER HUB REMOVAL

1.Using special tool Bearing remover (MD998917), support the 5th speed gear, and then set them on the press.
2.Push down on the input shaft with the press and remove the 5th speed-reverse synchronizer hub.

<<C>>5TH SPEED GEAR SLEEVE REMOVAL

1.Using special tool Bearing remover (MD998801), support the 4th speed gear, and then set them on the press.
2.Push down on the input shaft with the press and remove the 5th speed gear sleeve.

<<D>>4TH SPEED GEAR SLEEVE REMOVAL

1.Using special tool Bearing remover (MD998801), support the 3rd speed gear, and then set them on the press.
2.Push down on the input shaft with the press and remove the 4th speed gear sleeve.

<<E>> BALL BEARING REMOVAL

1.Using special tool Bearing remover (MD998801), support the ball bearing, and then set them on the press.
2.Push down on the input shaft with the press and remove the ball bearing.

REASSEMBLY SERVICE POINTS

>>A<< OIL SEAL INSTALLATION

Install the oil seal into the end of the input shaft as shown.

>>B<< BALL BEARING INSTALLATION

1.Using special tool Bearing remover (MD998801), support the 2nd speed gear portion of the input shaft, and then set them on the press.
2.Using special tools, press install the ball bearing with the press.

  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer adapter (MD998816)

>>C<< SNAP RING INSTALLATION

1.Install the thickest snap ring that can be fitted in the snap ring groove of input shaft.
2.Make sure that the front bearing axial play meets the standard value.
Standard value: 0 - 0.12 mm

>>D<< SYNCHRONIZER SPRING INSTALLATION

Install the synchronizer spring onto the synchronizer ring as shown.

>>E<< SYNCHRONIZER RING INSTALLATION
caution There are 3rd speed and 4th speed synchronizer rings, if the wrong one is installed it will effect the shift feeling.

1.Ascertain whether or not there are identification notches on the synchronizer ring.
Two notches: 3rd speed synchronizer ring
No notches: 4th speed synchronizer ring
2.Install the synchronizer ring so that it completely fits over the machined cone of the gear.

>>F<< 3RD-4TH SPEED SYNCHRONIZER HUB INSTALLATION

1.Using special tool Bearing remover (MD998801), support the 2nd speed gear portion of the input shaft, and then set them on the press.
2.Make sure that the synchronizer ring has been perfectly matched to the 3rd speed gear cone.
3.Check the installation direction of the 3rd-4th speed synchronizer hub, and put it on the input shaft.

4.Using special tools, press install the 3rd-4th speed synchronizer hub with the press.

  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer adapter (MD998825)
5.Make sure that the synchronizer ring can rotate freely.

>>G<< SYNCHRONIZER SLEEVE INSTALLATION

1.Check the installation direction of the synchronizer sleeve, and install it onto the 3rd-4th speed synchronizer hub.

2.Install the synchronizer sleeve so that the areas with teeth that have raised tips (three areas total) are aligned with the areas on the synchronizer hub that have deep grooves between the teeth (three areas total).

>>H<< 4TH SPEED GEAR SLEEVE INSTALLATION

1.Using special tool Bearing remover (MD998801), support the 2nd speed gear portion of the input shaft, and then set them on the press.
2.Using special tools, install the 4th speed gear sleeve with the press.

  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer adapter (MD998824)

>>I<< 5TH SPEED GEAR SLEEVE INSTALLATION

1.Using special tool Bearing remover (MD998801), support the 2nd speed gear portion of the input shaft, and then set them on the press.
2.Using special tools, install the 5th speed gear sleeve onto the input shaft with the press.

  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer adapter (MD998820)

>>J<< 5TH SPEED-REVERSE SYNCHRONIZER HUB INSTALLATION

1.Check that the 5th speed- reverse synchronizer hub is in the correct installation direction, and put it on the input shaft.

2.Using special tool Bearing remover (MD998801), support the input shaft gear, and then set them on the press.
3.Using special tools, install the 5th speed-reverse synchronizer hub with the press.

  • Installer cap (MD998812)
  • Installer adapter (MD998819)
4.Make sure that the synchronizer ring on the 5th speed gear side can rotate freely.

>>K<< SYNCHRONIZER SLEEVE INSTALLATION

1.Install the synchronizer sleeve so that the identification grooves are oriented in the direction shown.

2.When the synchronizer sleeve is installed, check that the deep groove portion of the synchronizer hub is aligned with the projecting portion of the sleeve.

>>L<< BALL BEARING INSTALLATION

1.Using special tool Bearing remover (MD998801), support the 2nd speed gear portion of the input shaft, and then set them on the press.
2.Using special tools, install the ball bearing onto the input shaft with the press.

  • Installer cap (MD998812)
  • Installer adapter (MD998818)

>>M<< SNAP RING INSTALLATION

1.Install the thickest snap ring that can be fitted in the groove of the input shaft.
2.Make sure that the rear bearing axial play meets the standard value.
Standard value:
    0 - 0.09 mm