Disassembly and Assembly
OUTPUT SHAFTDisassembly Steps 1-4:
Disassembly Steps 5-38:
DISASSEMBLY AND ASSEMBLY
DISASSEMBLY SERVICE POINTS
<> TAPER ROLLER BEARING REMOVAL
1. Using special tool MD998801, support the taper roller bearing, and then set them on the press.
2. Push down on the output shaft with the press, and take out the taper roller bearing.
<> REVERSE GEAR BEARING SLEEVE REMOVAL
1. Using special tool MD998801, support the reverse gear, and then set them on the press.
2. Push down on the output shaft with the press and remove the reverse gear bearing sleeve.
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1. Using special tool MD998801, support the 4th speed gear, and then set them on the press.
2. Push down on the output shaft with the press and remove the 5th speed-reverse synchronizer hub.
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1. Using special tool MD998917, support the 2nd speed gear, and then set them on the press.
2. Push down on the output shaft with the press and remove the 3rd speed gear.
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1. Using special tool MD998917, support the 1st speed gear, and then set them on the press.
2. Push down on the output shaft with the press and remove the 2nd speed gear sleeve.
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1. Using special tool MD998801, support the 1st speed gear sleeve, and then set them on the press.
2. Push down on the output shaft with the press and remove the 1st speed gear sleeve.
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1. Using special tool MD998801, support the taper roller bearing, and then set them on the press.
2. Push down on the output shaft with the press and remove the taper roller bearing.
ASSEMBLY SERVICE POINTS
>>A<< OIL SEAL INSTALLATION
Make sure that the oil seal is pressed into the position shown in the illustration.
>>B<< TAPER ROLLER BEARING INSTALLATION
1. Using special tool MD998801, support the output shaft gear, and then set them on the press.
2. Using special tools MD998812 and MD998819, press install the taper roller bearing with the press.
>>C<<1ST SPEED GEAR SLEEVE INSTALLATION
1. Set the output shaft on the press support stand.
2. Using special tools MD998812, MD998814, MD998824 and MD998364, press install the 1st speed gear sleeve with the press.
>>D<< SYNCHRONIZER SPRING INSTALLATION
Install the synchronizer spring to the illustrated position of the outer synchronizer ring.
>>E<< 1ST-2ND SPEED SYNCHRONIZER HUB INSTALLATION
1. Set the output shaft on the press support stand.
2. Check that the 1st-2nd speed synchronizer hub is in the correct installation direction, and put it on the output shaft.
3. Using special tools MD998812, MD998814, MD998824 and MD998364, press install the 1st-2nd speed synchronizer hub with the press.
4. Make sure that the outer synchronizer ring on the 1st speed gear side can rotate freely.
>>F<< SYNCHRONIZER SLEEVE INSTALLATION
1. Check that the synchronizer sleeve is in the correct direction for installation, and install it on the 1st-2nd speed synchronizer hub.
2. Install the synchronizer sleeve so that the areas with teeth that have raised tips (three areas total) are aligned with the areas on the synchronizer hub that have deep grooves between the teeth (three areas total).
>>G<< 2ND SPEED GEAR SLEEVE INSTALLATION
1. Set the output shaft on the press support stand.
2. Using special tools MD998812, MD998814, MD998824 and MD998364, press install the 2nd speed sleeve onto the output shaft.
>>H<< 3RD SPEED GEAR INSTALLATION
1. Check that the 2nd speed gear and the outer synchronizer ring have been properly installed. Also, make sure the claws on the synchronizer cone (four places) are correctly fitted into the holes in the 2nd speed gear (four places).
2. Using special tools MD998812, MD998814, MD998824 and MD998364, press install the 3rd speed gear onto the output shaft.
3. Make sure that the 2nd speed gear and the outer synchronizer ring can rotate freely.
>>I<< SNAP RING INSTALLATION
1. Install the thickest snap ring that can be fitted in the groove of output shaft.
2. Make sure that the 3rd speed gear end play meets the standard value.
Standard value: 0 - 0.09 mm (0 - 0.0035 inch)
>>J<< 4TH SPEED GEAR INSTALLATION
1. Set the output shaft on the press support stand.
2. Using special tools MD998812, MD998813, MD998821 and MD998364, press install the 4th speed gear onto the output shaft.
>>K<< 5TH SPEED GEAR SLEEVE INSTALLATION
Using special tools MD998812, MD998813, MD998821 and MD998364, press install the 5th speed gear sleeve onto the output shaft.
>>L<< SYNCHRONIZER SPRING INSTALLATION
Install the synchronizer spring to the illustrated position of the synchronizer ring.
>>M<< 5TH SPEED-REVERSE SYNCHRONIZER HUB INSTALLATION
1. Set the output shaft on the press support stand.
2. Make sure that the synchronizer ring is fitted correctly on the cone of the 5th speed gear.
3. Check that the 5th speed-reverse synchronizer hub is oriented correctly for installation, and fit it on the output shaft.
4. Using special tools MD998812, MD998813, MD998821 and MD998364, press install the 5th speed-reverse synchronizer hub with the press.
5. Make sure that the synchronizer ring on the 5th speed gear side can rotate freely.
>>N<< SYNCHRONIZER SLEEVE INSTALLATION
1. Check that the synchronizer sleeve is in the correct direction for installation, and install it on the 5th speed-reverse synchronizer hub.
2. Install the synchronizer sleeve so that the areas with teeth that have raised tips (three areas total) are aligned with the areas on the synchronizer hub that have deep grooves between the teeth (three areas total).
>>O<< REVERSE GEAR BEARING SLEEVE INSTALLATION
1. Make sure the synchronizer ring, reverse gear and needle roller bearing have been correctly installed.
2. Using special tools MD998812, MD998820 and MD998364, press fit the reverse gear sleeve. Make sure that the reverse gear and the synchronizer ring can rotate freely during the pressing process.
>>P<< TAPER ROLLER BEARING INSTALLATION
Using special tools MD998812, MD998819 and MD998364, press install the taper roller bearing.
>>Q<< SNAP RING INSTALLATION
1. Install the thickest snap ring that can be fitted in the groove of output shaft.
2. Make sure that the taper roller bearing end play meets the standard value.
Standard value: 0 - 0.09 mm (0 - 0.0035 inch)