Output Shaft Disassembly and Assembly

DISASSEMBLY AND ASSEMBLY









- MD998917: Bearing remover

- MD998368: Bearing installer

- MD998812: Installer cap

- MD998813: Installer-100

- MD998820: Installer adapter

- MD998814: Installer 200

- MD998819: Installer adapter

DISASSEMBLY SERVICE POINTS

[[A]] TAPERED ROLLER BEARING INNER RACE AND 4TH DRIVE GEAR REMOVAL





Using special tool MD998917, support the 4th drive gear and remove the tapered roller bearing Inner race and 4th drive gear.

[[B]] 3RD DRIVE GEAR AND 2ND GEAR REMOVAL





Using special tool MD998917, support the 2nd gear and remove the 3rd drive gear and 2nd gear.

[[C]] REVERSE GEAR, SYNCHRONIZER HUB NO.1 AND 1ST GEAR REMOVAL





Using special tool MD998917, support the 1st gear and remove the 1st gear, reverse gear and synchronizer hub No.1.

[[D]] TAPERED ROLLER BEARING INNER RACE REMOVAL





Using special tool MD998917 and MD998368, support the tapered roller bearing Inner race and remove the tapered roller bearing Inner race.
NOTE:
Since special tool MD998917 holds the tapered roller bearing at the roller portion, the roller portion is broken when the inner race is removed.

ASSEMBLY SERVICE POINTS

]]A[[ TAPERED ROLLER BEARING INNER RACE INSTALLATION





Using special tools MD998812, MD998813 and MD998820, install the tapered roller bearing inner race.

]]B[[ SYNCHRONIZER RING SET NO.1 (SYNCHRONIZER OUTER RING NO.1, SYNCHRONIZER MIDDLE RING NO.1, SYNCHRONIZER INNER RING NO.1) INSTALLATION

CAUTION:
The rings of the synchronizer ring set No. 1 and No. 2 are dedicated to the 1st and 2nd gears. Be sure to install the right ring set to the right gear.





1. Make sure that the synchronizer outer ring of the synchronizer ring set No. 1 is as shown.





2. Install the synchronizer ring set No. 1 aligning the claws of the synchronizer middle ring to the positioning holes in the 1st gear.
NOTE:
Apply gear oil to the sufficiently on the sliding surface

]]C[[ REVERSE GEAR AND SYNCHRONIZER HUB NO.1 INSTALLATION





1. Install the reverse gear onto the synchronizer hub in the illustrated direction.
NOTE:
Apply gear oil to the sufficiently on the sliding surface





2. Using special tools MD998812, MD998814 and MD998819, install the synchronizer hub and reverse gear.
3. After installation, confirm the 1st gear slides smoothly.

]]D[[ SYNCHRONIZER RING SET NO.2 (SYNCHRONIZER OUTER RING NO.2, SYNCHRONIZER MIDDLE RING NO.2, SYNCHRONIZER INNER RING NO.2) AND 2ND GEAR INSTALLATION

CAUTION:
The rings of the synchronizer ring set No. 1 and No. 2 are dedicated to the 1st and 2nd gears. Be sure to install the right ring set to the right gear.





1. Make sure that the synchronizer outer ring of the synchronizer ring set No. 2 is as shown.





2. Install the synchronizer ring set No. 2 to the 2nd gear aligning the claws of the synchronizer middle ring to the positioning holes in the 2nd gear.
NOTE:
Apply gear oil to the sufficiently on the sliding surface

]]E[[ 3RD DRIVE GEAR INSTALLATION





Using special tools MD998812, MD998813 and MD998819, install the 3rd drive gear.

]]F[[ 4TH DRIVE GEAR INSTALLATION





Using special tools MD998812, MD998813 and MD998819, install the 4th drive gear.

]]G[[ TAPERED ROLLER BEARING INNER RACE INSTALLATION





Using special tools MD998812, MD998813 and MD998819, install the tapered roller bearing inner race.