DISASSEMBLY AND REASSEMBLY

			Disassembly steps
<<A>>	>>G<<	1.	Radial ball bearing
	>>F<<	2.	Synchromesh shifting key No.3 spring
	>>F<<	3.	Synchromesh shifting key No.3
	>>F<<	4.	Synchroniser clutch hub No.3
	>>F<<	5.	Synchromesh shifting key No.3 spring
	>>F<<	6.	Synchroniser clutch hub No.3
	>>F<<	7.	Synchroniser ring No.3
<<B>>		8.	5th gear sub-assembly
		9.	Needle roller bearing
		10.	Spacer
	>>E<<	11.	Ball
	>>D<<	12.	Snap ring
		13.	Thrust washer
		14.	4th gear sub-assembly
		15.	Needle roller bearing
		16.	Spacer
	>>C<<	17.	Snap ring
	>>B<<	18.	Synchroniser ring No.2
	>>B<<	19.	Synchromesh shifting key No.2 spring
<<C>>	>>B<<	20.	Synchromesh shifting key No.2
	>>B<<	21.	Synchroniser clutch hub No.2
	>>B<<	22.	Synchromesh shifting key No.2 spring
	>>B<<	23.	Synchroniser clutch hub No.2
	>>B<<	24.	Synchroniser ring No.2
		25.	3rd gear sub-assembly
		26.	Needle roller bearing
<<D>>	>>A<<	27.	Radial ball bearing
		28.	Input shaft

DISASSEMBLY SERVICE POINTS

<<A>> RADIAL BALL BEARING REMOVAL

1.Using special tool Bearing remover (MD998801), support the radial ball bearing, and then set them on the press.
2.Push down on the input shaft with the press and remove the radial ball bearing.

<<B>> 5TH GEAR SUB-ASSEMBLY REMOVAL

1.Using special tool Bearing remover (MD998801), support the 5th speed gear, and then set them on the press.
2.Push down on the input shaft with the press and remove the 5th speed-reverse synchroniser.

<<C>> 4TH GEAR SUB-ASSEMBLY/3RD GEAR SUB-ASSEMBLY REMOVAL

1.Using special tool Bearing remover (MD998801), support the 3rd gear, and then set them on the press.
2.Push down on the input shaft with the press and remove the 4th speed-reverse synchroniser and 3rd speed-reverse synchroniser.

<<D>> RADIAL BALL BEARING REMOVAL

1.Using special tool Bearing remover (MD998801), support the ball bearing, and then set them on the press.
2.Push down on the input shaft with the press and remove the radial ball bearing.

REASSEMBLY SERVICE POINTS

>>A<< RADIAL BALL BEARING INSTALLATION

1.Using special tools, press install the radial ball bearing with the press.

Installer cap (MD998812)
Installer-200 (MD998814)
Installer adapter (MD998816)

>>B<< SYNCHROMESH SHIFTING KEY No.2 SPRING/SYNCHROMESH SHIFTING KEY No.2/SYNCHRONISER CLUTCH HUB No.2/SYNCHRONISER RING No.2 INSTALLATION

1.Synchroniser ring No.2 and synchroniser clutch hub No.2 are attached beforehand and it is made synchroniser assembly.

2.Check that the synchroniser clutch hub No.2 and synchroniser ring No.2 is in the correct installation direction, and put it on the output shaft.

3.Using special tools, install the synchroniser clutch hub No.2 with the press.

Installer cap (MD998812)
Installer-200 (MD998814)
Installer adapter (MD998820)

4.Make sure that the outer synchroniser ring on the 5th gear sub-assembly side can rotate freely.

>>C<< SNAP RING INSTALLATION

1.Install the thickest snap ring that can be fitted in the groove of the input shaft.

2.Make sure that the rear bearing axial play meets the standard value.
Standard value: 0 - 0.1 mm

>>D<< SNAP RING INSTALLATION

1.Install the thickest snap ring that can be fitted in the groove of the input shaft.
2.Make sure that the rear bearing axial play meets the standard value.
Standard value: 0 - 0.1 mm

>>E<< BALL INSTALLATION

1.A ball is installed in the input shaft.
2.Next a Needle roller bearing is installed in the input shaft.

>>F<< SYNCHROMESH SHIFTING KEY No.3 SPRING/SYNCHROMESH SHIFTING KEY No.3/SYNCHRONISER CLUTCH HUB No.3/SYNCHRONISER RING No.3 INSTALLATION

1.Synchroniser ring No.3 and synchroniser clutch hub No.3 are attached beforehand and it is made synchroniser assembly.

2.Check that the synchroniser clutch hub No.3 and synchroniser ring No.3 is in the correct installation direction, and put it on the output shaft.

3.Using special tools, install the synchroniser clutch hub No.3 with the press.

Installer cap (MD998812)
Installer-200 (MD998814)
Installer adapter (MD998817)

4.Make sure that the outer synchroniser ring on the 5th gear sub-assembly side can rotate freely.

>>G<< RADIAL BALL BEARING INSTALLATION

1.Using special tools, install the radial ball bearing onto the input shaft with the press.

Installer cap (MD998812)
Installer-100 (MD998813)
Installer adapter (MD998818)