Output Shaft Disassembly and Assembly

DISASSEMBLY AND ASSEMBLY









- 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.