Mainshaft And Gear

MAINSHAFT AND GEAR


Disassembly and Assembly


GENERAL PRECAUTIONS
- Never reuse snap ring.
- Secure mainshaft in a vise with backplate, and then remove gears and snap rings.





- For installation and removal of snap ring, set snap ring pliers and flat pliers at both sides of snap ring. While expanding snap ring with snap ring pliers, move snap ring with flat pliers.
- Disassemble gear components putting direction marks on the parts that never affect any functions.

DISASSEMBLY
1. Remove 3rd-4th synchronizer hub and 3rd baulk ring.





2. Remove snap ring (1) and thrust washer (2) using suitable tools.
3. Remove 3rd main gear (1) and thrust washer (2).





4. Remove snap ring (1) and thrust washer (2) using suitable tools.
5. Remove 2nd main gear (1) and thrust washer (2).





6. Remove snap ring (1), and then remove 2nd inner baulk ring, 2nd synchronizer cone, and 2nd outer baulk ring.
7. Remove 1st-2nd coupling sleeve, insert keys, springs, and 1st-2nd synchronizer hub.





8. Remove 1st outer baulk ring, 1st synchronizer cone, 1st inner baulk ring, and 1st main gear (2).

INSPECTION AFTER DISASSEMBLY

Mainshaft and Gear
Check the following items and replace if necessary.





- Damage, peeling, bend, uneven wear, and distortion of shaft
- Excessive wear, damage, and peeling of gear






Synchronizer
Check the following items and replace if necessary.
- Contact surface breakage, damage, and unusual wear of coupling sleeve, synchronizer hub, insert key, and spring.





- Coupling sleeve and synchronizer hub move smoothly.
- Breakage, damage, and excessive wear of baulk ring cam surface and insert contact surface






Bearing
Check bearing for damage and unsmooth rotation. Replace if necessary.

ASSEMBLY
Note the following items, and assemble in the reverse order of disassembly. Refer to Exploded View.






CAUTION:
- Never reuse snap ring.
- Check that snap ring is securely installed to the groove.
- Apply gear oil to 3rd baulk ring.
- Apply gear oil to 1st outer baulk ring, 1st synchronizer cone, and 1st inner baulk ring.
- Apply gear oil to 2nd outer baulk ring, 2nd synchronizer cone, and 2nd inner baulk ring.
- Replace 1st outer baulk ring, 1st synchronizer cone, and 1st inner baulk ring as a set.
- Replace 2nd outer baulk ring, 2nd synchronizer cone, and 2nd outer baulk ring as a set.





- Be careful with the orientation of 1st-2nd synchronizer hub.
- A: 1st main gear side
- B: 2nd main gear side
- Replace 1st-2nd synchronizer hub and 1st-2nd coupling sleeve as a set.





- Be careful with the orientation of 1st-2nd coupling sleeve.
- A: 2nd main gear side
- B: 1st main gear side





- Be careful with the orientation of 3rd-4th synchronizer hub.
- A: 4th main gear side
- B: 3rd main gear side
- Replace 3rd-4th synchronizer hub and 3rd-4th coupling sleeve as a set.





- Be careful with the orientation of insert key (1) and spring (2).