Disassembly and Assembly

INPUT SHAFT

DISASSEMBLY AND ASSEMBLY

Removal Steps 1-14:

Removal Steps 15-31:

Required Special Tools:
^ MD998917: Bearing remover
^ MB990842: Drag link bushing remover and installer B
^ MD998812: Installer cap
^ MD998813: Installer-100
^ MD998819: Installer adapter (40)
^ MD998822: Installer adapter (46)
^ MD999601: Valve stem seal installer

DISASSEMBLY SERVICE POINTS

[A] 5TH SPEED GEAR / SYNCHRONIZER INNER RING / SYNCHRONIZER CONE / SYNCHRONIZER OUTER RING / 5TH SPEED SYNCHRONIZER HUB / TAPER ROLLER BEARING SYNCHRONIZER KEY STOPPER PLATE / 5TH SPEED SYNCHRONIZER SLEEVE REMOVAL





Using the special tools, MD998917 and MB990842, indicated below, remove the 5th speed gear, 5th speed synchronizer sleeve, 5th speed synchronizer hub, synchronizer inner ring, synchronizer outer ring, synchronizer cone, synchronizer key stopper plate and taper roller bearing.

[B] 3RD SPEED GEAR / 5TH SPEED GEAR SLEEVE / 4TH SPEED GEAR / NEEDLE ROLLER BEARING / 4TH SPEED GEAR SLEEVE / SYNCHRONIZER OUTER RING / SYNCHRONIZER CONE / SYNCHRONIZER INNER RING / 3RD-4TH SPEED SYNCHRONIZER SLEEVE / 3RD-4TH SPEED SYNCHRONIZER HUB / THRUST BEARING / 3RD SPEED GEAR REMOVAL





Using special tool, MD998917, support the 3rd speed gear, and then remove the 3rd seed gear, thrust bearings, 3rd-4th speed synchronizer sleeve, 3rd-4th speed synchronizer hub, synchronizer outer ring, synchronizer inner ring, synchronizer cone, 4th speed gear, needle roller bearing, 4th speed gear sleeve and 5th speed gear sleeve.

[C] TAPER ROLLER BEARING REMOVAL





Using special tool, MD998917, remove the taper roller bearing.

ASSEMBLY SERVICE POINTS

[A] TAPER ROLLER BEARING INSTALLATION





Using the special tools, MD998812, MD998813 and MD998819, indicated below, install the taper roller bearing.

[B] THRUST BEARING INSTALLATION





Install the thrust bearings as shown.

[C] 3RD-4TH SPEED SYNCHRONIZER HUB 3RD-4TH SPEED SYNCHRONIZER SLEEVE INSTALLATION





1. Install the 3rd-4th speed synchronizer hub and synchronizer sleeve in the illustrated direction.





2. Using the special tools, MD998812, MD998813 and MD998822, indicated below, install the 3rd-4th speed synchronizer sleeve, 3rd-4th speed synchronizer hub, synchronizer outer ring, synchronizer inner ring and synchronizer cone.
3. After installation, check that the 3rd speed gear rotates smoothly.

[D] 4TH SPEED GEAR SLEEVE INSTALLATION





Using the special tools, MD998812, MD998813 and MD998822, indicated below, install the 4th speed gear sleeve.

[E] 5TH SPEED GEAR SLEEVE INSTALLATION





Using the special tools, MD998812, MD998813 and MD998822, indicated below, install the 5th speed gear sleeve.

[F] 5TH SPEED SYNCHRONIZER HUB / 5TH SYNCHRONIZER SLEEVE INSTALLATION





1. Install the 5th speed synchronizer hub and synchronizer sleeve in the illustrated direction.





2. Using the special tools, MD998812, MD998813 and MD998822, indicated below, install the 5th speed synchronizer hub and synchronizer sleeve.
3. After installation, check that the 5th speed gear rotates smoothly.

[G] TAPER ROLLER BEARING INSTALLATION





Using the special tools, MD998812, MD998813 and MD998822, indicated below, press-fit the taper roller bearing.

[H] SNAP RING INSTALLATION





Select and install appropriate snap ring onto the input shaft so that the clearance of the taper roller bearing meets the standard value.
Standard value: 0.01 - 0.09 mm (0.0004 - 0.0035 inch)

[I] OIL SEAL INSTALLATION





Using special tool, MD999601, drive the oil seal as deep as shown into place.