DISASSEMBLY AND REASSEMBLY


1.
 Shaft snap ring


2.
 Tapered roller bearing


3.
 6th gear sub-assembly


4.
 Synchronizer outer ring No.3


5.
 Needle roller bearing


6.
 Spacer


7.
 Shaft snap ring


8.
 Trans mission clutch hub No.3


9.
 Transmission hub sleeve No.3


10.
 Synchromesh shifting key No.1


11.
 Ball


12.
 Synchromesh shifting key spring


13.
 Synchronizer outer ring No.3


14.
 5th gear sub-assembly


15.
 Spacer


16.
 Needle roller bearing


17.
 Spacer


18.
 Shaft snap ring


19.
 Synchromesh clutch hub No.4


20.
 Transmission hub sleeve No.4


21.
 Synchronizer ring No.4


22.
 Synchromesh shifting key No.3


23.
 Synchromesh shifting spring


24.
 Reverse gear


25.
 Needle roller bearing


26.
 Tapered roller bearing


27.
 Output shaft No.2

DISASSEMBLY

1.Remove the shaft snap ring.

2.Using special tool Bearing remover (MD998917), support the 6th gear sub-assembly and remove the tapered roller bearing and 6th gear sub-assembly.

3.Remove the synchronizer outer ring No.3.

4.Remove the needle roller bearing and spacer.

5.Remove the shaft snap ring.

6.Using special tool Bearing remover (MD998917), support the 5th gear sub-assembly and remove the transmission hub sleeve No.3, synchromesh shifting key No.1, ball, synchromesh shifting key spring, transmission clutch hub No.3, synchronizer outer ring No.3 and 5th gear sub-assembly.

7.Remove the spacer and needle roller bearing.

8.Remove the spacer.

9.Remove the shaft snap ring.

10.Using special tool Bearing remover (MD998917), support the reverse gear and remove the transmission hub sleeve No.4, synchromesh shifting key No.3, synchromesh shifting spring, transmission clutch hub No.4, synchronizer ring No.4 and reverse gear.
11.Remove the needle roller bearing.

12.Using special tool Bearing remover (MD998917), support the tapered roller bearing and remove the tapered roller bearing.

REASSEMBLY

1.Using special tools, install the tapered roller bearing.

  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer adapter (MD998819)

2.Install the needle roller bearing and reverse gear to output shaft No.2.
3.Install the synchronizer ring No.4.

4.As shown in the illustration, install the synchromesh shifting key No.3 and the synchromesh shifting spring.

5.Install the synchromesh shifting key No.3 to the transmission clutch hub No.4 so that the claw is positioned as shown in the illustration.

6.Combine the transmission clutch hub No.4 with the transmission hub sleeve No.4 in the direction as shown in the illustration.
note
  • Apply gear oil to the caulked area between the sleeve and the hub.
  • After installation, confirm the sleeve and the hub slide smoothly.

7. Set the transmission hub sleeve No.4, transmission clutch hub No.4 to the output shaft No.2 in the direction as shown in the illustration.
note
  • Install the 1st-2nd synchronizer assembly securely into the stopper of the output shaft No.2.
  • Check for smooth rotation of the gear after the installation.

8.Install the synchronizer ring No.4, aligning the projection in the synchronizer hub with the groove in position shown in the illustration.

9.Using special tools, install the transmission clutch hub No.4.

  • Installer cap (MD998812)
  • Installer-200 (MD998814)
  • Installer adapter (MD998827)
note
  • Confirm correct position as shown.
  • The synchronizer ring must not bind.

10.Select a shaft snap ring that allows distance of the thrust crevice of reverse hub to fall within the standard value range.
Standard value: 0 - 0.1 mm

11.Install the spacer to output shaft No.2.

12.Install the needle roller bearing and spacer to output shaft No.2.

13.Install the 5th gear sub-assembly to output shaft No.2, and synchronizer outer ring No.3 to 5th gear sub-assembly.

14.As shown in the illustration, set the ball, synchromesh shifting key No.1, synchromesh shifting key spring, transmission clutch hub No.3, transmission hub sleeve No.3.
note
  • Apply gear oil to the caulked area between the sleeve and the hub.
  • After the installation, confirm the sleeve and the hub slide smoothly.

15. Set the transmission hub sleeve No.3, transmission clutch hub No.3 to the output shaft No.2 in the direction as shown in the illustration.

16.Using special tools, install the transmission clutch hub No.3.

  • Installer cap (MD998812)
  • Installer-200 (MD998814)
  • Installer adapter (MD998827)
note
  • During press fit, confirm correct positions of the hub and the synchronizer ring.
  • Install the 5th-6th synchronizer assembly securely into the stopper of the output shaft No.2.
  • After installation, confirm the sleeve and the hub slide smoothly.
  • The synchronizer ring must not bind.

17.Select a shaft snap ring that allows distance of the thrust crevice of transmission clutch hub No.3 to fall within the standard value range.
Standard value: 0 - 0.1 mm

18.Install the spacer and needle roller bearing to output shaft No.2.

19.Install the synchronizer outer ring No.3 to transmission hub sleeve No.3, transmission clutch hub No.3.

20.Install the 6th gear sub-assembly to output shaft No.2.

21.Using special tools, install the tapered roller bearing.

  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer adapter (MD998819)

22.Install the shaft snap ring to output shaft No.2.
Standard value: 0 - 0.1 mm