Mainshaft Disassembly/Inspection/Reassembly

Disassembly





1. Remove the angular ball bearing (A) and the tapered cone ring using a commercially available bearing separator (B) and a commercially available bearing puller (C). Be sure the bearing separator is under the tapered cone ring.





2. Support 5th gear (A) on steel blocks, and press the mainshaft out of the 5th synchro hub (B). Use of a jaw-type puller can damage the gear teeth.





3. Support the 3rd gear (A) on steel blocks, and press the mainshaft out of the 3rd/4th synchro hub (B). Use of a jaw-type puller can damage the gear teeth.

Mainshaft Inspection





1. Inspect the gear surface and bearing surface for wear and damage, then measure the mainshaft at points A, B, and C. If any part of the mainshaft is less than the service limit, replace it with a new one.
Standard:
A Ball bearing surface (transmission housing side): 27.987 - 28.000 mm (1.1019 - 1.1024 inch)
B Distance collar surface: 31.984 - 32.000 mm (1.2594 - 1.2598 inch)
C Needle bearing surface: 38.984 - 39.000 mm (1.5348 - 1.5354 inch)
D Ball bearing surface (clutch housing side): 27.977 - 27.990 mm (1.1015 - 1.1020 inch)
E Bushing surface: 20.80 - 20.85 mm (0.8189 - 0.8209 inch)
Service Limit:
A: 27.94 mm (l.100 inch)
B: 31.93 mm (1.257 inch)
C: 38.93 mm 11.533 inch)
D: 27.94 mm (1.100 inch)
E: 20.75 mm (0.817 inch)





2. Inspect the runout by supporting both ends of the mainshaft. Rotate the mainshaft two complete revolutions when measuring the runout. If the runout is more than the service limit, replace the mainshaft with a new one.
Standard: 0.02 mm (0.001 inch) maximum
Service Limit: 0.05 mm (0.002 inch)

Reassembly

Special Tools Required
^ Driver, 40 mm I.D. 07746-0030100
^ Attachment, 30 mm I.D. 07746-0030300

NOTE: Refer to the Exploded View as needed during this procedure.

1. Clean all the parts in solvent, dry them, and apply lubricant to all contact surfaces except the 3rd/4th and 5th synchro hubs.
2. Install the needle bearing and 3rd gear on the mainshaft.





3. Install the double cone synchro assembly (A) by aligning the synchro cone fingers (B) with the holes in 3rd gear (C), then install the synchro spring (D).





4. Install the 3rd/4th synchro hub (A) by aligning the synchro cone fingers (B) with the grooves in 3rd/ 4th synchro hub (C).





5. Install the 3rd/4th synchro hub (A) using the special tool.





6. Install the 3rd/4th synchro sleeve (A) by aligning the stops (B) with the 3rd/4th synchro sleeve and hub. After installing, check the operation of the 3rd/ 4th synchro hub set.





7. Install the synchro spring (A).
8. Install the double cone synchro assembly (B) by aligning the synchro cone fingers (C) with the grooves in the 3rd/4th synchro hub (D).





9. Install 4th gear (A) by aligning the synchro cone fingers (B) with holes in 4th gear (C).
10. Install the needle bearings, distance collar, 5th gear, and 5th gear synchro spring and ring.





11. Install the 5th synchro hub (A) by aligning the synchro cone fingers (B) with the grooves in the 5th/6th synchro hub (C).





12. Install the 5th synchro hub (A) using the special tools.
13. Install the 5th synchro sleeve.





14. Install the synchro spring (A).
15. Install the synchro ring (B) by aligning the synchro cone fingers (C) with the grooves in the 5th synchro hub (D).





16. Install the new ball bearing (A) using the special tools and press (B).