Mainshaft Assembly

Disassemble

Fig. 8 High Speed Hub Removal:

Fig. 9 Reverse Gear Bushing & Bearing Removal:

Fig. 10 Sleeve Hub Assembly Removal:

1. Separate input shaft and mainshaft assemblies.
2. Remove input shaft needle bearing, then the high speed hub assembly circlip.
3. Remove high speed sleeve-hub assembly, synchronizer ring and third gear, using split plate tool No. J22912-01 and a suitable press, Fig. 8.
4. Remove third gear needle bearing, then the circlip from rear of mainshaft.
5. Remove rear bearing using split plate tool No. J22912-01 and a suitable press.
6. Remove 5th gear washer, steel ball, gear, synchronizer ring and needle bearing.
7. Remove reverse sleeve-hub assembly circlip.
8. Remove reverse sleeve-hub assembly using split plate tool No. J22912-01 and a suitable press.
9. Remove reverse gear and reverse gear needle bearing.
10. Remove bearing washer, steel ball and reverse gear bushing using split plate tool No. J22912-01 and a suitable press, Fig. 9.
11. Remove mainshaft bearing using split plate tool No. J22912-01 and a suitable press.
12. Remove bearing washer, steel ball, low gear, low gear synchronizer and low gear needle bearing.
13. Remove low gear bushing, low speed sleeve-hub assembly, second gear and second gear synchronizer, using split plate tool No. J22912-01 and a suitable press, Fig. 10.
14. Remove second gear needle bearing.

Inspection

Fig. 11 Bearing & Bushing Inspection:

Fig. 12 Synchronizer Inspection:

Fig. 13 Checking Sleeve & Fork Clearance:

1. Check ball bearings for smooth operation and replace as necessary.
2. Check needle bearings and contacting surfaces, Fig. 11, replace as necessary.
3. Check clearance A between synchronizer ring and gear, Fig. 12.
4. Check key slot width B in synchronizer ring, Fig. 12.
5. Check synchronizer rings and gears for excessive wear or damage and replace as necessary.
6. Check clearance between sleeve and shifter fork, Fig. 13, and replace parts as necessary.

Assemble

Fig. 14 Second Gear & Synchronizer Ring Installation:

Fig. 15 Low Speed Sleeve Hub Assembly Installation:

Fig. 16 Steel Ball & Bearing Installation:

1. Install second gear needle bearing, gear and synchronizer ring, Fig. 14.
2. Install low speed sleeve-hub assembly using bearing installer tool No. J37753 and a suitable press, Fig. 15.
3. Install low gear bushing using bearing installer tool No. J37753 or equivalent.
4. Install low gear needle bearing, synchronizer ring and low gear.
5. Install steel ball and bearing washer, Fig. 16.
6. Install reverse gear bushing using bearing installation tool Nos. J37753 and J35664.
7. Install reverse gear needle bearing, then the reverse gear.
8. Install reverse sleeve-hub using bearing installation tool Nos. J37753 and J35664.
9. Install outer circlip on mainshaft.
10. Install 5th gear synchronizer ring, needle bearing, gear, steel ball and washer. Ensure oil slot in washer faces 5th gear.
11. Install rear bearing using bearing installation tool No. J28406 and a suitable press, then install circlip.
12. Install third gear needle bearing, third gear, synchronizer ring and high speed sleeve-hub assembly using hub installation tool No. J35425 or equivalent.
13. Install circlip, then the input shaft needle bearing.
14. Install high speed synchronizer ring, then the input shaft.