Disassembly and Assembly
OUTPUT SHAFTDISASSEMBLY AND ASSEMBLY
Removal Steps 1-27:
Required Special Tools:
^ MB990560: Rear axle shaft bearing remover
^ MB990842: Drag link bushing remover and installer B
^ MD998917: Bearing remover
^ MD998812: Installer cap
^ MD998814: Installer-200
^ MD998824: Installer adapter (50)
^ MD998822: Installer adapter (46)
^ MD998813: Installer-100
^ MD998821: Installer adapter (44)
^ MD998819: Installer adapter (40)
^ MD999601: Valve stem seal installer
DISASSEMBLY SERVICE POINTS
[A] TAPER ROLLER BEARING REMOVAL
1. Using a chisel or the like, knock off the roller cage of the taper roller bearing.
2. Using the special tools, MB990842 and MB990560, indicated below, remove the taper roller bearing.
[B] TAPER ROLLER BEARING REMOVAL
Using the special tools, MD998917 and MB990842, indicated below, remove the taper roller bearing.
[C] 5TH SPEED GEAR / 4TH SPEED GEAR REMOVAL
Using the special tools, MD998917 and MB990842, indicated below, remove the 5th speed gear and 4th speed gear.
[D] 3RD SPEED GEAR REMOVAL
Using special tool, MD998917, remove the 3rd speed gear.
[E] NEEDLE ROLLER BEARING / SYNCHRONIZER CONE / SYNCHRONIZER OUTER RING / SYNCHRONIZER INNER RING THRUST BEARING / 2ND SPEED GEAR SLEEVE 1ST-2ND SPEED SYNCHRONIZER HUB / 1ST SPEED GEAR / 1ST SPEED GEAR SLEEVE REMOVAL
Using special tool, MD998917, support the 1st speed gear sleeve, and then remove the 2nd speed gear sleeve, 1st-2nd speed synchronizer hub, synchronizer cones, synchronizer outer rings, synchronizer inner rings, thrust bearings, 1st speed gear, needle roller bearing and 1st speed gear sleeve.
ASSEMBLY SERVICE POINTS
[A] 1ST SPEED GEAR SLEEVE INSTALLATION
Using the special tools, MD998812, MD998814 and MD998824, indicated below, install the 1st speed gear sleeve.
[B] THRUST BEARING INSTALLATION
Install the thrust bearings as shown.
[C] 1ST-2ND SPEED SYNCHRONIZER HUB INSTALLATION
1. Install the 1st-2nd speed synchronizer hub in the illustrated direction.
2. Using the special tools, MD998812, MD998814 and MD998824, indicated below, install the 1st-2nd speed synchronizer hub.
[D] 1ST-2ND SPEED SYNCHRONIZER SLEEVE INSTALLATION
1. Install the 1st-2nd speed synchronizer sleeve in the illustrated direction.
2. Install the synchronizer outer ring, synchronizer cone and synchronizer inner ring.
3. After installation, check that the 1st-2nd speed gears rotate smoothly.
[E] 2ND SPEED GEAR SLEEVE INSTALLATION
Using the special tools, MD998812, MD998814 and MD998824, indicated below, install the 2nd speed gear sleeve.
[F] 3RD SPEED GEAR INSTALLATION
Using the special tools, MD998812, MD998814 and MD998822, indicated below, install the 3rd speed gear.
[G] SNAP RING INSTALLATION
Select and install appropriate snap ring onto the output shaft so that the clearance of the output shaft-3rd speed gear meets the standard value.
Standard value: 0.01 - 0.09 mm (0.0004 - 0.0035 inch)
[H] 4TH SPEED GEAR INSTALLATION
Using the special tools, MD998812, MD998813 and MD998821, indicated below, install the 4th speed gear.
[I] 5TH SPEED GEAR INSTALLATION
Using the special tools, MD998812, MD998813 and MD998819, indicated below, install the 5th speed gear.
[J] TAPER ROLLER BEARING INSTALLATION
Using the special tools, MD998812, MD998813 and MD998819, indicated below, press-fit the taper roller bearing.
[K] SNAP RING INSTALLATION
Select and install appropriate snap ring onto the output 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)
[L] TAPER ROLLER BEARING INSTALLATION
Using the special tools, MD998812 and MD998819, indicated below, install the taper roller bearing.
[M] OIL SEAL INSTALLATION
Using special tool, MD999601, drive the oil seal as deep as shown into place.
