Output Shaft

Output Shaft





Disassembly





1. CAUTION: Only loosely attach the special tool to avoid damaging the synchronizer ring.

Using the special tool, remove the taper roller bearing together with the reverse gear wheel.
- Discard the tapper roller bearing.





2. Remove the needle roller bearing and the synchronizer ring.
1. Remove the needle roller bearing.
2. Remove the synchronizer ring.





3. Remove the fifth and reverse gear synchronizer assembly.
1. Remove the snap ring.
2. Remove the synchronizer assembly. Discard the snap ring.





4. Remove the fifth gear
1. Remove the synchronizer ring.
2. Remove the fifth gear.
3. Remove the needle roller bearing.





5. Using the special tool, remove the fourth gear wheel.
- Remove and discard the snap ring.





6. Using the special tool, remove the second and third gear wheel.





7. Remove the second gear synchronizer.
1. Remove the needle roller bearing.
2. Remove the inner synchronizer ring.
3. Remove the synchronizer cone.
4. Remove the outer synchronizer ring.





8. Remove the first and second gear synchronizer assembly.
1. Remove the snap ring.
2. Remove the synchronizer assembly. Discard the snap ring.





9. Remove the first gear wheel with the double synchronizer and needle roller bearing.
1. Remove the outer synchronizer ring.
2. Remove the synchronizer cone.
3. Remove the inner synchronizer ring.
4. Remove the first gear wheel.
5. Remove the needle roller bearing.





10. Using the special tool, press the taper roller bearing off the output shaft.
- Discard the tapper roller bearing.





11. CAUTION: Take care when removing the selector ring from the synchronizer hub. The detent balls are spring-loaded.

NOTE: Mark the location of the selector ring.

Dismantle the synchronizer assembly.
1. Remove the selector ring.
2. Remove the synchronizer hub.
3. Remove the compression spring.
4. Remove the blocker bar.
5. Remove the detent ball.

Assembly

CAUTION: Immerse the double synchronizer units in manual transmission fluid before assembly.

1. Carefully clean and check all sliding parts and lubricate them with manual transmission fluid before assembly.





2. NOTE: Do not oil taper roller bearings, which are being re-used.

Install the first gear wheel double synchronizer and needle roller bearing.
1. Install the needle roller bearing.
2. Install the first gear wheel.
3. Install the inner synchronizer ring.
4. Install the synchronizer cone.
5. Install the outer synchronizer ring.





3. NOTE: Assemble the synchronizer to the original marked position.

Assemble the first and second gear synchronizer.
1. Insert the compression springs.
2. Insert the blocker bar and detent balls against the spring pressure.
3. Install the selector ring.





4. NOTE: Install the synchronizer ring hub with the small collar and the annular groove of the selector ring facing outwards.

NOTE: Install a new snap ring.

Install the first and second gear synchronizer assembly.
1. Install the first and second gear synchronizer assembly.
2. Install the snap ring.





5. NOTE: Do not oil tapper roller bearings, which are being re-used.

Install the second gear wheel and second gear synchronizer.
1. Install the needle roller bearing.
2. Install the outer synchronizer ring.
3. Install the synchronizer cone.
4. Install the inner synchronizer ring.
5. Install the second gear wheel.





6. Using the special tool, install the third gear wheel.





7. NOTE: Install a new snap ring.

Using the special tool, install the fourth gear wheel.
- Install the snap ring.





8. Install the fifth gear.
1. Install the needle roller bearing.
2. Install fifth gear.
3. Install the synchronizer ring.





9. NOTE: Install the synchronizer hub with the small collar and the annular groove forwards.

Installation position of the synchronizer assembly.





10. NOTE: Install a new snap ring.

Install fifth and reverse gear synchronizer assembly.
1. Install the synchronizer assembly.
2. Install the snap ring.





11. Install the reverse gear.
1. Install the synchronizer ring.
2. Install the needle roller bearing.
3. Install the reverse gear wheel.





12. NOTE: Install a new taper roller bearing.

Using a suitable tube, install the taper roller bearing.





13. NOTE: Install a new taper roller bearing.

Using a suitable tube, install the taper roller bearing.