DISASSEMBLY AND REASSEMBLY



Disassembly steps

>>E<<
 1.
 Snap ring
<<A>>
 >>D<<
 2.
 Radial ball bearing


3.
 4th gear sub-assembly


4.
 Needle roller bearing


5.
 Spacer

>>C<<
 6.
 Snap ring


7.
 Synchronizer ring No.4
<<B>>
 >>B<<
 8.
 Synchronizer clutch hub No.2
<<B>>
 >>B<<
 9.
 Synchronizer hub sleeve No.2


10.
 Synchromesh shifting key No.2


11.
 Compression spring


12.
 Synchronizer ring No.3
<<B>>
13.
 3rd gear sub-assembly


14.
 Needle roller bearing


15.
 Snap ring
<<C>>
 >>A<<
 16.
 Cylindrical roller bearing


17.
 Input shaft

DISASSEMBLY SERVICE POINTS

<<A>> RADIAL BALL BEARING REMOVAL

Using special tool Bearing remover (MD998917), support the radial ball bearing and remove the radial ball bearing.

<<B>> SYNCHRONIZER HUB SLEEVE No.2, SYNCHRONIZER CLUTCH HUB No.2 AND 3RD GEAR SUB-ASSEMBLY REMOVAL

Using special tool Bearing remover (MD998917), support the 3rd gear sub- assembly and remove the 3rd gear sub- assembly, synchronizer hub sleeve No.2 and synchronizer clutch hub No.2.

<<C>> CYLINDRICAL ROLLER BEARING REMOVAL


Using special tool Rear axle shaft bearing remover (MB990560), support the cylindrical roller bearing and remove the cylindrical roller bearing.

REASSEMBLY SERVICE POINTS

>>A<< CYLINDRICAL ROLLER BEARING INSTALLATION

1.Check the installation direction of the cylindrical roller bearing

2.Using special tools to install the cylindrical roller bearing.

  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer adapter (MD998818)

>>B<< SYNCHRONIZER CLUTCH HUB No.2 AND SYNCHRONIZER HUB SLEEVE No.2 INSTALLATION

1.Before assembly, make sure that the hub and sleeve face the correct direction.
note
  • Apply gear oil to the caulked area between the sleeve and the hub.
  • After installation, confirm the sleeve and the hub slide smoothly.

2.Using special tools to install the synchronizer hub sleeve No.2 and synchronizer clutch hub No.2.

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

>>C<< SNAP RING INSTALLATION



Select a snap ring that allows distance of the thrust crevice of synchronizer hub No.2 to fall within the standard value range.
Standard value: 0 - 0.1 mm
note Try on snap rings in the decreasing order of thickness, and install the first one that fits into the input shaft.

>>D<< RADIAL BALL BEARING INSTALLATION



1.Before assembly, make sure that the radial ball bearing faces the correct direction.

2.Using special tools to install the radial ball bearing.

  • Installer cap (MD998812)

  • Installer-100 (MD998813)

  • Installer adapter (MD998820)

>>E<< SNAP RING INSTALLATION

Select a snap ring that allows distance of the thrust crevice of radial ball bearing to fall within the standard value range.
Standard value: 0 - 0.1 mm
note Try on snap rings in the decreasing order of thickness, and install the first one that fits into the input shaft.