Disassembly

GEAR COMPONENTS


Disassembly






1. Before removing gears and shafts, measure each gear end play. Gear End Play.
- If not within specification, disassemble and check contact surface of gear to hub, washer, bushing, needle bearing and shaft.





2. Remove rear side components on mainshaft and counter gear.
a. Remove reverse coupling sleeve.





b. Remove mainshaft rear snap ring and counter gear rear snap ring using suitable tool.
c. Remove C-ring holder and mainshaft C-rings from mainshaft using suitable tool.





d. Remove counter gear rear end bearing using suitable tool.
e. Remove reverse idler thrust washer, reverse idler gear and reverse idler needle bearings.
f. Remove mainshaft rear bearing using Tools.










g. Remove reverse main gear together with mainshaft spacer and reverse synchronizer hub using suitable tool. Then remove reverse gear needle bearings.





h. Remove reverse counter gear using suitable tool.
i. Remove OD coupling sleeve together with OD baulk ring, reverse baulk ring and spring inserts.





j. Remove reverse gear bushing using suitable tool.





k. Remove OD counter gear and reverse cone using suitable tool.
l. Remove OD gear needle bearing.
m. Remove reverse idler shaft.
3. Press out mainshaft, OD main gear, OD gear bushing and counter gear alternately using Tool.















4. Remove front side components on mainshaft.
a. Remove 1st gear washer and steel ball using suitable tool.

CAUTION:
Be careful not to lose steel ball.
b. Remove 1st main gear and 1st gear needle bearing.





c. Press out 2nd main gear together with 1st gear bushing and 1st and 2nd synchronizer assembly using Tool.






d. Remove 2nd gear needle bearing.
e. Remove mainshaft front snap ring.





f. Press out 3rd main gear together with 3rd and 4th synchronizer assembly.
g. Remove 3rd gear needle bearing.





5. Remove front side components on counter gear.
a. Remove counter gear rear thrust bearing using Tool.










b. Remove sub-gear snap ring, sub-gear bracket and steel ball using suitable tool.





6. Remove main drive gear bearing.
a. Remove spacer and pilot bearing.
b. Remove main drive gear snap ring.
c. Press out main drive gear bearing using Tool.






7. Remove bearing retainer.
8. Remove bearings from case components using Tools.










9. Remove mainshaft front bearing snap ring from mainshaft front bearing.