Disassembly and Assembly

DISASSEMBLY

Gear End Play:

1. Before disassembly, check 3rd, 4th and 5th input gear end plays.
If not within specification, disassemble and check contact surface of gear, shaft and hub. Then check clearance of snap ring and thrust washer - Refer to Assembly below.




2. Remove input shaft rear bearing.




3. Remove 5th synchronizer and 5th input gear.




4. Remove thrust washer ring, thrust washers and 4th input gear.




5. Remove snap ring.




6. Remove 3rd & 4th synchronizer and 3rd input gear.




7. Remove input shaft front bearing.

ASSEMBLY










1. Place inserts in the three grooves on the coupling sleeve (3rd & 4th synchronizer, 5th synchronizer).

Snap Ring Of 3rd & 4th Synchroniser Hub:

2. Install 3rd input gear and 3rd baulk ring.
3. Press on 3rd & 4th synchronizer hub.

Note: Pay attention to its direction.

4. Select proper snap ring of 3rd & 4th synchronizer hub to minimize clearance of groove, and then install it.
Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 in)

Input Shaft Thrust Washer:

5. Install 4th input gear.
6. Select proper thrust washers to minimize clearance of groove.
Then install them and thrust washer ring.
Allowable clearance of groove: 0 - 0.06 mm (0 - 0.0024 in)




7. Install 5th input gear.
8. Press on 5th synchronizer.







9. Install input shaft front and rear bearings.
10. Measure gear end play as the final check - Refer to "Disassembly" above.