Mainshaft: Service and Repair

Disassembly

1. Disassemble the drive pinion gear assembly and main shaft assembly.
2. Remove the needle bearing from the drive pinion gear.
3. Remove the snap ring of front ball bearing.




4. Remove the front ball bearing by using press.




5. Remove the 5th synchronizer ring from main shaft assembly.
6. Remove the snap ring of the 5&6th synchronizer assembly.

End play : 0 - 0.08L





7. Remove the double angular ball bearing, 1&2nd synchronizer hub&sleeve assembly, synchronizer ring and 2nd gear assembly altogether by using press on the 2nd gear.




8. Remove the roller bearing.




9. Remove the 5&6th synchronizer hub&sleeve assembly, synchronizer ring and 6th gear assembly altogether by using press on the 6th clutch gear.




10. Remove the needle roller bearing.

Reassembly

1. Install the roller bearing.




2. Install the 2nd gear assembly with the synchronizer ring assembly.




3. Temporarily install the 1&2nd synchronizer hub.

CAUTION:
Place the chamfer inside of the synchronizer hub downward.




4. Install the 1st gear sleeve with 1&2nd synchronizer hub by using press and the special service tool(09432-25100).

CAUTION:
Check that the grooves aligns the 1&2nd synchronizer hub and the synchronizer ring.




5. Install the 1&2nd synchronizer sleeve.

CAUTION:
Be careful not to be upside down.








6. Install the 1&2nd synchronizer keys at 3 places.




7. Install the synchronizer ring assembly.




8. Install the roller bearing.




9. Install the 1st gear assembly.




10. Install the double angular ball bearing by using press and the special service tool(09432-H1000).




11. Install the needle roller bearing.




12. Install the 6th gear assembly.




13. Install the synchronizer ring.




14. Install the 5&6th synchronizer hub by using press and the special service tool(09221-21000).

CAUTION:
Check that the shapes aligns the 5&6th synchronizer hub and the synchronizer ring.
Place the chamfer inside of the synchronizer hub downward.




15. Install the snap ring of 5&6th synchronizer assembly.

End play : 0 - 0.08L


CAUTION:
Be sure to use a new snap ring.




16. Install the 5&6th synchronizer sleeve.




17. Install the 5&6th synchronizer keys at 3 places.




18. Install the front ball bearing by using press and the special service tool(09432-2C100).




19. Install the snap ring of front ball bearing.

CAUTION:
Be sure to use a new snap ring.




20. Install the needle roller bearing.




21. Install the synchronizer ring.




22. Reassemble the drive pinion gear assembly and the main shaft assembly.