Primary Shaft Pre-Inspect/Disassembly

PRIMARY SHAFT PRE-INSPECT/DISASSEMBLY
1. Measure the thrust clearances of all gears before disassembly, refer to Pre-Inspection.
2. Disassemble in the order shown, Refering to the Disassembly Notes.

PRE-INSPECTION

3rd Gear Thrust Clearance





1. Measure the clearance between 3rd gear and 2nd gear.

Clearance: 0.002 - 0.008 inch (0.05 - 0.20 mm)
Maximum: 0.010 inch (0.26 mm)

2. If the clearance exceeds the maximum, check the contact surfaces of the 3rd gear, 2nd gear and clutch hub (3rd/4th). Replace worn or damaged parts.

4th Gear Thrust Clearance





1. Measure the clearance between 4th gear and the ball bearing.

Clearance: 0.007 - 0.015 inch (0.17 - 0.37 mm)
Maximum: 0.017 inch (0.44 mm)

2. If the clearance exceeds the maximum, check the contact surfaces of the 4th gear, ball bearing and clutch hub (3rd/4th). Replace worn or damaged parts.


DISASSEMBLY NOTES





Bearing and 4th Gear

CAUTION: Hold the shaft with one hand so that it does not fall.





1. Remove the ball bearing and 4th gear with a standard bearing puller.

3rd/4th Clutch Hub Assembly, Synchronizer Ring (3rd) And 3rd Gear

CAUTION: Hold the shaft with one hand so that it does not fall.

1. Remove the retaining ring.





2. Remove the 3rd/4th clutch hub assembly, synchronizer ring (3rd) and 3rd gear with a standard bearing puller.

Bearing





1. Remove the bearing with the SST (or equivalent).