Assembly

MAINSHAFT AND GEAR

Assembly


CAUTION:
- Select mainshaft rear bearing adjusting shim, as per the following procedure when replacing mainshaft adjusting shim, 6th main gear, 5th main gear, or 4th main gear.
- Replace mainshaft adjusting shim.
- If new mainshaft adjusting shim is thinner than previous one, offset the thickness difference by selecting thicker mainshaft rear bearing adjusting shim.
- If new mainshaft adjusting shim is thicker than previous one, offset the thickness difference by selecting thinner mainshaft rear bearing adjusting shim.
- Replace 6th main gear, 5th main gear, or 4th main gear.
- Measure the thickness of the main gear used before and the new main gear
- Increase the thickness of the mainshaft rear bearing adjusting shim, if the difference is smaller than 0.025 mm (0.0010 in).
- Replace transaxle assembly when replacing mainshaft.





- For installation 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.





1.Install mainshaft front bearing inner race (1), using the drift (A)
[SST: ST-36720030 ( - )].

CAUTION:
Replace mainshaft front bearing outer race and mainshaft front bearing inner race as a set.
2.Apply gear oil to 1st inner baulk ring, 1st synchronizer cone, 1st outer baulk ring, 2nd inner baulk ring, 2nd synchronizer cone, and 2nd outer baulk ring.

CAUTION:
- Replace 1st inner baulk ring, 1st synchronizer cone, and
1st outer baulk ring as a set.
- Replace 2nd inner baulk ring, 2nd synchronizer cone, and
2nd outer baulk ring as a set.
3.Install insert keys and 1st-2nd coupling sleeve to 1st-2nd synchronizer hub.

CAUTION:
Replace 1st-2nd synchronizer hub and 1st-2nd coupling sleeve as a set.





4.Install 1st main gear (1), 1st inner baulk ring, 1st synchronizer cone, 1st outer baulk ring, 1st-2nd synchronizer hub assembly (2), 2nd inner baulk ring, 2nd synchronizer cone, and 2nd outer baulk ring.
5.Install bushing (3), using the drift (A) [SST: KV-32102700 ( - )].





6.Install 3rd main gear (1) and 2nd main gear (2), using the drift (A) [SST: KV-32102700 ( - )].





7.Measure dimension "L" as shown in the figure. Select mainshaft adjusting shim (1) according to the following list, and then install it to mainshaft.





Unit: mm (in)















8.Install 4th main gear (1), using the drift (A) [SST: KV-32102700 ( )].





9.Install 5th main gear (1), using the drift (A) [SST: KV-32102700 ( )].





10.Install 6th main gear (1), using the drift (A) [SST: KV-32102700 ( )].





11.Install mainshaft rear bearing inner race (1), using the drift (A)
[SST: ST-30901000 (J-26010-01)].

CAUTION:
Replace mainshaft rear bearing inner race and mainshaft rear bearing outer race as a set.
12.Install snap ring.

CAUTION:
Never reuse snap ring.