3rd to 6th Gear Assembly Overview, Removing and Installing

3rd to 6th gear assembly overview, removing and installing - 6 Spd. M/T 01X Front Wheel Drive

Sequence for disassembling and assembling

Note:
^ 3rd to 6th speed selector gears should have an axial play of 0.20to 0.50mm after installing.





1 - Bearing housing

^ With input shaft and output shaft

2 - Oil collector

^ With magnet
^ Clipped into reverse shaft support.

3 - Circlip

^ Install thickest circlip that will still just fit.
^ Re-determining thickness

4 - 6th gear wheel
5 - Spacer sleeve
6 - 5th gear wheel

^ Installation position: high inside collar faces 4th gear wheel

7 - 4th gear wheel

^ Installation position: high inside collar faces 5th gear wheel

8 - Circlip

^ Install thickest circlip that will still just fit.
^ Re-determining thickness

9 - 3rd gear wheel

^ Installation position: machined side faces reverse gear synchronizing hub

10 - Thrust washer

^ For 3rd speed selector gear

11 - Needle bearing

^ For 3rd gear

12 - 3rd speed selector gear

^ Insert spring before installing
^ Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

13 - 3rd gear synchro-ring

^ Checking for wear

14 - Circlip

^ Mark

15 - Synchronizing hub for 3rd and 4th gear

^ Installation position: high inside collar faces 3rd speed selector gear

16 - Circlip

^ Re-determining thickness

17 - Locking collar for 3rd and 4th gear

^ Mark position in relation to synchronizing hub prior to removing

18 - Selector fork for 3rd and 4th gear
19 - Pin with clip

^ For securing selector fork for 3rd and 4th gear to selector rod

20 - 4th gear synchro-ring

^ Checking for wear

21 - 4th speed selector gear

^ Insert spring before installing
^ Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

22 - Needle bearing

^ For 4th gear

23 - Thrust washer

^ For 4th speed and 5th speed selector gears

24 - Needle bearing inner race

^ For 5th gear

25 - Needle bearing

^ For 5th gear

26 - 5th speed selector gear

^ Insert spring before installing
^ Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

27 - 5th gear synchro-ring

^ Checking for wear

28 - Synchronizing hub for 5th and 6th gear
29 - Locking collar for 5th and 6th gear

^ Mark position in relation to synchronizing hub prior to removing

30 - Needle bearing inner race

^ For 6th gear

31 - Needle bearing

^ For 6th gear

32 - 6th gear synchro-ring

^ Checking for wear

33 - 6th speed selector gear

^ Insert spring before installing
^ Check axial clearance after installing using feeler gauge (0.20 to 0.50 mm)

34 - Thrust washer

^ For 6th speed selector gear

35 - Inner race

^ For needle roller bearing

36 - Multi-point socket head bolt, 150Nm
37 - Selector fork for 5th and 6th gear
38 - Pin with clip

^ For securing selector fork for 5th and 6th gear to selector rod