DISASSEMBLY AND REASSEMBLY

			Disassembly steps
	>>R<<	1.	Snap ring
<<A>>	>>Q<<	2.	Ball bearing
<<B>>	>>P<<	3.	Reverse gear sleeve
		4.	Needle roller bearing
		5.	Reverse gear
	>>M<<	6.	Synchronizer ring
	>>L<<	7.	Synchronizer spring
	>>O<<	8.	Synchronizer sleeve
<<C>>	>>N<<	9.	5th speed-reverse synchronizer hub
	>>M<<	10.	Synchronizer ring
	>>L<<	11.	Synchronizer spring
		12.	5th speed gear
		13.	Needle roller bearing
	>>K<<	14.	5th speed gear sleeve
	>>J<<	15.	4th speed gear
	>>I<<	16.	Snap ring
<<D>>	>>H<<	17.	3rd speed gear
		18.	2nd speed gear
		19.	Needle roller bearing
<<E>>	>>G<<	20.	2nd speed gear sleeve
		21.	Inner synchronizer ring
		22.	Synchronizer cone
		23.	Outer synchronizer ring
	>>D<<	24.	Synchronizer spring
	>>F<<	25.	Synchronizer sleeve
	>>E<<	26.	1st-2nd speed synchronizer hub
		27.	Outer synchronizer ring
	>>D<<	28.	Synchronizer spring
		29.	Inner synchronizer ring
		30.	Synchronizer cone
		31.	1st speed gear
		32.	Needle roller bearing
<<F>>	>>C<<	33.	1st speed gear sleeve
	>>B<<	34.	Snap ring
<<G>>	>>A<<	35.	Roller bearing inner race
		36.	Output shaft

DISASSEMBLY SERVICE POINTS

<<A>> BALL BEARING REMOVAL

1.Using special tool Bearing remover (MD998917), support the ball bearing, and then set them on the press.
2.Push down on the output shaft with the press, and remove the ball bearing.

<<B>> REVERSE GEAR BEARING SLEEVE REMOVAL

1.Using special tool Bearing remover (MD998801), support the reverse gear, and then set them on the press.
2.Push down on the output shaft with the press and remove the reverse gear bearing sleeve.

<<C>> 5TH SPEED-REVERSE SYNCHRONIZER HUB REMOVAL

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

<<D>> 3RD SPEED GEAR REMOVAL

1.Using special tool Bearing remover (MD998917), support the 2nd speed gear, and then set them on the press.
2.Push down on the output shaft with the press and remove the 3rd speed gear.

<<E>> 2ND SPEED GEAR SLEEVE REMOVAL

1.Using special tool Bearing remover (MD998917), support the 1st speed gear, and then set them on the press.
2.Push down on the output shaft with the press and remove the 2nd speed gear sleeve.

<<F>> 1ST SPEED GEAR SLEEVE REMOVAL

1.Using special tool Bearing remover (MD998801), support the 1st speed gear sleeve, and then set them on the press.
2.Push down on the output shaft with the press and remove the 1st speed gear sleeve.

<<G>> ROLLER BEARING INNER RACE REMOVAL

1.Using special tool Bearing remover (MD998917), support the roller bearing inner race, and then set them on the press.
2.Push down on the output shaft with the press and remove the roller bearing inner race.

REASSEMBLY SERVICE POINTS

>>A<< ROLLER BEARING INNER RACE INSTALLATION

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 adapter (MD998818)

>>B<< SNAP RING INSTALLATION

1.Install the thickest snap ring that can be fitted in the groove of output shaft.
2.Make sure that the front bearing inner race end play meets the standard value.
Standard value: 0 - 0.12 mm

>>C<<1ST SPEED GEAR SLEEVE INSTALLATION

1.Set the output shaft on the press support stand.

2.Using special tools, install the 1st speed gear sleeve with the press.

Installer cap (MD998812)
Installer-200 (MD998814)
Installer adapter (MD998825)

>>D<< SYNCHRONIZER SPRING INSTALLATION

Install the synchronizer spring onto the outer synchronizer ring as shown.

>>E<< 1ST-2ND SPEED SYNCHRONIZER HUB INSTALLATION

1.Set the output shaft on the press support stand.

2.Check that the 1st-2nd speed synchronizer hub is in the correct installation direction, and put it on the output shaft.

3.Using special tools, install the 1st-2nd speed synchronizer hub with the press.

Installer cap (MD998812)
Installer-200 (MD998814)
Installer adapter (MD998825)

4.Make sure that the outer synchronizer ring on the 1st speed gear side can rotate freely.

>>F<< SYNCHRONIZER SLEEVE INSTALLATION

1.Check that the synchronizer sleeve is in the correct direction for installation, and install it on the 1st-2nd speed synchronizer hub.

2.Install the synchronizer sleeve so that the areas with teeth that have raised tips (three areas total) are aligned with the areas on the synchronizer hub that have deep grooves between the teeth (three areas total).

>>G<< 2ND SPEED GEAR SLEEVE INSTALLATION

1.Set the output shaft on the press support stand.

2.Using special tools, install the 2nd speed sleeve onto the output shaft with the press.

Installer cap (MD998812)
Installer-200 (MD998814)
Installer adapter (MD998822)

>>H<< 3RD SPEED GEAR INSTALLATION

1.Check that the 2nd speed gear and the outer synchronizer ring have been properly installed. Also, make sure the claws on the synchronizer cone (four places) are correctly fitted into the holes in the 2nd speed gear (four places).

2.Using special tools, install the 3rd speed gear onto the output shaft with the press.

Installer cap (MD998812)
Installer-200 (MD998814)
Installer adapter (MD998822)

3.Make sure that the 2nd speed gear and the outer synchronizer ring can rotate freely.

>>I<< SNAP RING INSTALLATION

1.Install the thickest snap ring that can be fitted in the groove of output shaft.
2.Make sure that the 3rd speed gear end play meets the standard value.
Standard value: 0 - 0.09 mm

>>J<< 4TH SPEED GEAR INSTALLATION

1.Set the output shaft on the press support stand.

2.Using special tools, install the 4th speed gear onto the output shaft with the press.

Installer cap (MD998812)
Installer-100 (MD998813)
Installer adapter (MD998819)

>>K<< 5TH SPEED GEAR SLEEVE INSTALLATION

Using special tools, install the 5th speed gear sleeve onto the output shaft with the press.

Installer cap (MD998812)
Installer-100 (MD998813)
Installer adapter (MD998819)

>>L<< SYNCHRONIZER SPRING INSTALLATION

Install the synchronizer spring onto the synchronizer ring as shown.

>>M<< SYNCHRONIZER RING INSTALLATION

caution

There is a 5th speed synchronizer ring and a reverse synchronizer ring. Be careful not to confuse the two when installing, as a mistake can effect the shift feeling.

1.Check for the presence of identification notches on the synchronizer ring.
No notches: 5th speed synchronizer ring
Three notches: Reverse synchronizer ring
2.Install the synchronizer ring so that it fits completely over the machined cone of the gear.

>>N<< 5TH SPEED-REVERSE SYNCHRONIZER HUB INSTALLATION

1.Set the output shaft on the press support stand.

2.Make sure that the synchronizer ring is fitted correctly on the cone of the 5th speed gear.

3.Check that the 5th speed-reverse synchronizer hub is oriented correctly for installation, and fit it on the output shaft.

4.Using special tools, press install the 5th speed-reverse synchronizer hub with the press.

Installer cap (MD998812)
Installer-100 (MD998813)
Installer adapter (MD998819)

5.Make sure that the synchronizer ring on the 5th speed gear side can rotate freely.

>>O<< SYNCHRONIZER SLEEVE INSTALLATION

1.Check that the synchronizer sleeve is in the correct direction for installation, and install it on the 5th speed-reverse synchronizer hub.

>>P<< REVERSE GEAR SLEEVE INSTALLATION

1.Make sure the synchronizer ring, reverse gear and needle roller bearing have been correctly installed.

2.Using special tools, press fit the reverse gear sleeve. Make sure that the reverse gear and the synchronizer ring can rotate freely during the pressing process.

Installer cap (MD998812)
Installer adapter (MD998818)

>>Q<< BALL BEARING INSTALLATION

1.Check the installation direction of the ball bearing.

2.Using special tools, install the ball bearing with the press.

Installer cap (MD998812)
Installer adapter (MD998818)

>>R<< SNAP RING INSTALLATION

1.Install the thickest snap ring that can be fitted in the groove of output shaft.
2.Make sure that the rear bearing end play meets the standard value.
Standard value: 0 - 0.09 mm