1ST/2ND GEAR COMPONENT, 5TH/6TH GEAR COMPONENT AND COUNTERSHAFT DISASSEMBLY

D5E051117030M03

Caution
• Remove the countershaft center bearing race only if there is a malfunction.

1. Disassemble in the order indicated in the table.

1
Needle bearing
2
Scoop ring
3
Maindrive gear shaft bearing
4
Maindrive gear shaft
5
Retaining ring
6
Needle bearing
7
Synchronizer ring
8
Clutch hub sleeve
9
5th/6th clutch hub
10
Synchronizer key spring
11
Synchronizer key
12
Thrust washer
13
Synchronizer ring
14
6th gear
15
Needle bearing
16
Mainshaft center bearing
17
Needle bearing race
18
Needle bearing
19
1st gear
20
Inner cone
21
Double cone
22
Synchronizer ring
23
Clutch hub sleeve
24
1st/2nd clutch hub
25
Synchronizer key spring
26
Synchronizer key
27
Synchronizer ring
28
Double cone
29
Inner cone
30
Friction damper
31
2nd gear
32
Needle bearing
33
Countershaft center bearing race
34
Countershaft front bearing race
35
Countershaft
36
Mainshaft

5th/6th Clutch Hub Component Disassembly Note

1. Remove the retaining ring using the two flathead screwdrivers.

Caution
• Do not reuse the retaining ring.

2. Supporting the 5th/6th clutch hub with your hand as shown in the figure, tap the mainshaft with a plastic hammer to remove the 5th/6th clutch hub.

1st/2nd Clutch Hub Component Disassembly Note

1. Using a press, remove the mainshaft center bearing, 1st gear, 1st synchronizer ring component, 1st/2nd clutch hub component, 2nd synchronizer ring component and 2nd gear at the same time.

Caution
• Be sure to support the mainshaft component so that it does not fall.

Maindrive Gear Shaft Bearing Disassembly Note

1. Remove the maindrive gear shaft bearing using the SST and press.

Countershaft Center Bearing Race Disassembly Note

1. Remove the countershaft center bearing race using the SST and press.

Caution
• Be sure to support the countershaft so that it does not fall.

Countershaft Front Bearing Race Disassembly Note

1. Remove the countershaft front bearing race using the SST.