Mainshaft W/Input Shaft
MAINSHAFT W/INPUT SHAFTDESCRIPTION
DISASSEMBLY
1. Disassemble the geartrain housing.
2. Mount the main shaft in a vise with protective jaws.
3. Remove first gear idler gear using special tool 938 and 1126.
4. Remove the reverse gear synchronizer assembly (1).
5. Remove the synchronizer ring (1) and idler gear (2) for reverse gear.
6. Remove first gear needle bearing (1) and sleeve (2).
7. Remove the thrust washer (1), first gear idler gear (2), and first gear idler needle bearing (3).
8. Remove the friction ring (1), cone ring (2), and the synchronizer ring (3).
9. Remove the locking ring (1) using pliers. Remove the 1st/2nd gear synchronizer using special tool 938 and 1126.
10. Remove the synchronizer ring (1), cone ring (2), and friction ring (3).
11. Remove the second gear idler gear (1) and needle bearing (2).
12. Remove the main shaft (1) from the input shaft (2).
13. Remove the synchronizer ring (5) and the clutch body (4).
14. Remove the cylindrical roller bearing (3) from the input shaft (2).
15. Remove the input shaft (2) from the vise.
16. Clamp the main shaft (3) in the vise with input end up.
17. Remove the locking ring (1), pull off the synchronizer cone (2) and the clutch body using special tool 938 and 1126.
18. Remove the synchronizer ring (1) and the clutch body (2).
19. Remove the 6th gear idler gear (1) and needle bearing (2).
20. Remove the main shaft (3) from the vise.
ASSEMBLY
1. Install the 6th gear needle bearing (2) and gear (1) on the mainshaft (3).
2. Install the clutch body (2) and the synchronizer ring (1).
NOTE: The inscription on the synchronizer body must face upwards (towards the input end). The drivers on the synchronizer ring must engage in the grooves in the synchronizer body.
3. Assemble the synchronizer if it is not being replaced.
4. Press on the 5th/6th gear synchronizer assembly (1).
NOTE: Snap rings that are bent or otherwise damaged must be replaced.
5. Install the snap ring (1) on the mainshaft (2). Check that it is fully seated.
6. Install the synchronizer ring (2). Be sure the drivers on the synchronizer ring are engaged in the grooves of the synchronizer body.
7. Oil the cylindrical bearing (2) and place it in the input shaft (1).
8. Place the input shaft (1) on the mainshaft.
9. Invert the mainshaft with input shaft in the vise. Use protected vise jaws.
10. Install the second gear needle bearing (3), and second gear (2) on the mainshaft (1) with the collar facing upwards.
11. Install the friction ring (4), the cone ring (3), and the synchronizer ring (2). The lobes in the friction ring (4) must engage in the recesses of the synchronizer ring (3).
12. Assemble the 1st/2nd gear synchronizer if it is not being replaced.
13. Install the 1st/2nd gear synchronizer assembly (1).
NOTE: Do not over expand the snap ring.
14. Install the snap ring (1).
NOTE: The lobes on the friction ring (1) must engage in the recesses in the synchronizer ring (3).
15. Install the synchronizer ring (3), the cone ring (2), and the friction ring (1).
16. Install the first gear needle bearing (3), first gear (2), and press on the 1st gear thrust washer (1).
17. Press on the sleeve (2), and the reverse gear needle bearing (1).
NOTE: The reverse gear collar must face upwards.
18. Install the reverse gear (2), and the synchronizer ring (1).
19. Press on the reverse gear synchronizer assembly (1).
20. Remove the input shaft together with the main-shaft from the vise.
21. Assemble the geartrain housing.