Mainshaft: Service and Repair

REMOVAL
1. Remove the mainshaft and the countershaft assemblies with the shift forks from the clutch housing.

NOTE: Tape the mainshaft spline before removing the mainshaft and the countershaft assemblies.





2. Remove the spring washer and the washer.





3. Remove the differential assembly from the clutch housing.





4. Remove the chamber plate.

DISASSEMBLE





1. Remove the ball bearing using a bearing puller as shown.

CAUTION: Remove the synchro hubs using a press and the steel blocks as shown. Use of a jaw-type puller can cause damage to the gear teeth.





2. Support 5th gear on steel blocks, and press the mainshaft out of the 5th synchro hub, as shown.





3. Support 3rd gear on steel blocks, and press the mainshaft out of the 3rd/4th synchro hub, as shown.

INSPECTION
Inspect mainshaft Testing and Inspection.

ASSEMBLE

CAUTION:
- Press the 3rd/4th and the 5th synchro hubs on the mainshaft without lubrication.
- When installing the 3rd/4th and the 5th synchro hubs, support the mainshaft on steel blocks, and install the synchro hubs using a press.
- Install the 3rd/4th and the 5th synchro hubs with a maximum pressure of 19.6 kN (14,466 lbs.).





1. Support 2nd gear on steel blocks, then install the 3rd/4th synchro hub using the special tools and a press, as shown.

NOTE:
- After installing, check the operation of the 3rd/4th synchro sleeve and hub.
- Assemble the 3rd/4th synchro hub and sleeve together before installing them on the mainshaft.





2. Install the 5th synchro hub using the special tools and a press as shown.





3. Install the ball bearing using the special tools and a press as shown.

NOTE: Install the ball bearing with the tapered end facing down.