DISASSEMBLY AND REASSEMBLY

Disassembly steps <<A>> >>H<< 1. Tapered roller bearing >>G<< 2. Snap ring <<B>> >>F<< 3. 5th driven gear <<B>> >>E<< 4. 4th driven gear 5. Output gear spacer <<C>> >>D<< 6. 3rd driven gear <<C>> 7. 2nd gear 8. Needle roller bearing 9. Spacer >>C<< 10. Snap ring 11. Synchroniser ring No.1 12. Synchromesh shifting key No.1 spring 13. Synchromesh shifting key No.1 <<D>> >>B<< 14. Synchroniser clutch hub No.1 15. Synchromesh shifting key No.1 spring 16. Reverse gear 17. Synchroniser ring No.1 <<D>> >>B<< 18. 1st gear 19. Needle roller bearing <<E>> >>A<< 20. Tapered roller bearing 21. Output shaft

1.Using special tools, support the tapered roller bearing, and then set them on the press. Bearing remover (MD998801) 2.Push down on the output shaft with the press, and remove the tapered roller bearing.

1.Using special tool Bearing remover (MD998801), support the 4th driven gear, and then set them on the press. 2.Push down on the output shaft with the press and remove the 5th driven gear and 4th driven gear.

1.2.Using special tool Bearing remover (MD998801), support the 2nd gear and remove the 3rd drive gear and 2nd gear.

1.Using special tool Bearing remover (MD998801), support the 1st gear and remove the 1st gear, reverse gear and synchroniser clutch hub No.1.

1. caution Be careful so as not to injure anything but tapered roller bearing. The cage of tapered roller bearing is cut using cold chisel and a roller is removed.

2.Apply special tool Bearing remover (MD998801) to the inner race and drive out it with a press.

1.Using special tool Bearing remover (MD998801), support the output shaft gear, and then place them on a press. 2.Using special tools, install the roller bearing inner race with the press. Installer cap (MD998812) Installer-200 (MD998814) Installer adapter (MD998816)

2.Check that the synchroniser clutch hub No.1 and synchroniser ring No.1 is in the correct installation direction, and put it on the output shaft.

3.Using special tools, install the 1st-2nd speed synchroniser hub with the press. Installer cap (MD998812) Installer-200 (MD998814) Installer adapter (MD998820) 4.Make sure that the outer synchroniser ring on the 1st speed gear side can rotate freely.

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

2.Using special tools, install the 3rd speed gear onto the output shaft with the press. Installer cap (MD998812) Installer-200 (MD998814) Installer adapter (MD998818) 3.Make sure that the 2nd speed gear and the outer synchroniser ring can rotate freely.

1.Using special tools, install the 4th speed gear onto the output shaft with the press. Installer cap (MD998812) Installer-200 (MD998814) Installer adapter (MD998818)

1.Using special tools, install the 5th speed gear onto the output shaft with the press. Installer cap (MD998812) Installer-200 (MD998814) Installer adapter (MD998818)

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

1.Using special tool Bearing remover (MD998801), support the output shaft gear, and then set them on the press. 2.Using special tools, install the roller bearing inner race with the press. Installer cap (MD998812) Installer-200 (MD998814) Installer adapter (MD998816)