FREE WHEELING CLUTCH DISASSEMBLY AND REASSEMBLY







Disassembly steps
<<A>>

1.
Main shaft assembly
<<A>>
>>F<<
2.
Bearing

>>E<<
3.
Spacer


4.
Clutch sleeve

>>D<<
5.
Spring pin


6.
Snap ring


7.
Shift fork


8.
Shift rod

>>C<<
9.
Oil seal
<<B>>
>>B<<
10.
Clutch gear
<<B>>
>>B<<
11.
Bearing

>>A<<
12.
Oil seal


13.
Clutch housing

DISASSEMBLY SERVICE POINTS



<<A>> MAIN SHAFT ASSEMBLY/BEARING REMOVAL


caution Do not allow the mainshaft to drop.

1.After special tool rear axle shaft bearing remover (MB990560) has been installed as shown, tighten the nut of special tool MB990560 until portion "A" of special tool MB990560 touches the bearing outer race.
2.Press out the mainshaft from the bearing.

<<B>> CLUTCH GEAR/BEARING REMOVAL



1.Use a press and iron piece to remove the clutch gear and bearing together.

2.Using a press, hold the supports against the bearing inner race, and separate the clutch gear and bearing.

REASSEMBLY SERVICE POINTS



>>A<< OIL SEAL INSTALLATION



Use special tool differential oil seal installer (MB991168) to tap the oil seal until it is flush with the clutch housing.

>>B<< BEARING/CLUTCH GEAR INSTALLATION



1.Use special tool ball joint remover and installer A (MB990799) to press-fit the bearing to the shoulder of the clutch gear.
caution Place special tool MB990890 or MB990891 against the outer race of the bearing.

2.Use special tool rear suspension bushing base (MB990890 or MB990891) to press-fit the bearing to the side of the clutch housing.

>>C<< COIL SEAL INSTALLATION



Use the following special tools to press-fit the oil seal to the housing tube.

  • Installer adapter (MB990926)
  • Installer bar (MB990938)

>>D<< SPRING PIN INSTALLATION



Tap the spring pin from the chamfered side of the shaft rod until the projection length becomes the length shown in the illustration.

>>E<< SPACER INSTALLATION



1.Place the current spacer in the area shown in the illustration to check that the dimensions shown in the illustration are within the standard values.
Standard Value (A) : 0.05 - 0.3 mm
2.If the dimensions are outside of the standard values, select the correct spacer type to fit in the standard values.
Part Number
Thickness mm
Part Number
Thickness mm
MR111526
1.1
MR111530
2.1
MR111527
1.35
MR111531
2.35
MR111528
1.6
MR111532
2.6
MR111529
1.85
MR111533
2.85

>>F<< BEARING INSTALLATION



Press-fit the bearing to the shoulder of the mainshaft.