DISASSEMBLY AND REASSEMBLY



Disassembly steps
<<A>>
1.
 3RD gear sleeve
<<B>>
2.
 Bearing
<<C>>
3.
 5TH speed gear and 5TH gear sleeve


4.
 5TH gear sleeve


5.
 Needle bearing


6.
 5TH speed gear


7.
 Synchronizer ring


8.
 Synchronizer key


9.
 5TH and 6TH synchronizer sleeve
<<D>>
10.
 5TH and 6TH synchronizer hub and 6TH speed gear


11.
 5TH and 6TH synchronizer hub


12.
 Synchronizer ring


13.
 6TH speed gear


14.
 Needle bearing


15.
 Snap ring
<<E>>
16.
 Bearing


17.
 Input shaft



Reassembly steps


17.
 Input shaft

>>A<<
 16.
 Bearing

>>B<<
 15.
 Snap ring


14.
 Needle bearing


13.
 6TH speed gear


12.
 Synchronizer ring

>>C<<
 11.
 5TH and 6TH synchronizer hub

>>D<<
 9.
 5TH and 6TH synchronizer sleeve


8.
 Synchronizer key


7.
 Synchronizer ring


6.
 5TH speed gear


5.
 Needle bearing

>>E<<
 4.
 5TH gear sleeve

>>F<<
 2.
 Bearing

>>G<<
 1.
 3RD gear sleeve

DISASSEMBLY SERVICE POINTS

<<A>> 3RD GEAR SLEEVE REMOVAL
1.Use special tool remover (MD998801) to support the 3RD gear sleeve.
2.Press the input shaft with a press and remove the 3RD gear sleeve.

<<B>> BEARING REMOVAL
1.Use special tool remover (MD998801) to support the bearing.
2.Press the input shaft with a press and remove the bearing.

<<C>> 5TH SPEED GEAR AND 5TH GEAR SLEEVE REMOVAL
1.Use special tool remover (MD998801) to support the 5TH speed gear and 5TH gear sleeve.
2.Press the input shaft with a press and remove the 5TH speed gear and 5TH gear sleeve.

<<D>> 5TH AND 6TH SYNCHRONIZER HUB AND 6TH SPEED GEAR REMOVAL
1.Use special tool remover (MD998801) to support the 5TH and 6TH synchronizer hub and 6TH speed gear.
2.Press the input shaft with a press and remove the 5TH and 6TH synchronizer hub and 6TH speed gear.

<<E>> BEARING REMOVAL
1.Use special tool remover (MD998801) to support the bearing.
2.Press the input shaft with a press and remove the bearing.

REASSEMBLY SERVICE POINTS

>>A<< BEARING INSTALLATION
1.Use special tools to install the bearing.

  • Installer cap (MD998812)
  • Installer-200 (MD998814)
  • Installer adapter (42) (MD998820)
2.Press the input shaft with a press and install the bearing.

>>B<< SNAP RING INSTALLATION
1.Install the thickest snap ring that can be fitted in the snap ring groove of the input shaft.
2.Make sure that the bearing end play meets the standard value.
Standard value: - 0.01 - 0.09 mm

>>C<< 5TH AND 6TH SYNCHRONIZER HUB INSTALLATION
1.The identification mark (2 mm-dia. circle) is stamped on the side of the 5th and 6th synchronizer hubs. These identification marks should face rearwards when these hubs are inserted into the input shaft.
2.Use special tools to install the 5TH and 6TH synchronizer hub.

  • Installer cap (MD998812)
  • Installer-200 (MD998814)
  • Installer adapter (50) (MD998824)
3.Press the input shaft with a press and install the 5TH and 6TH synchronizer hub.

>>D<< 5TH AND 6TH SYNCHRONIZER SLEEVE INSTALLATION

The identification groove on the 5th and 6th synchronizer sleeves should face towards the clutch housing when the sleeves are inserted into the input shaft.

>>E<< 5TH GEAR SLEEVE INSTALLATION
1.Use special tools to install the 5TH gear sleeve.

  • Installer cap (MD998812)
  • Installer-200 (MD998814)
  • Installer adapter (40) (MD998819)
2.Press the input shaft with a press and install the 5TH gear sleeve.

>>F<< BEARING INSTALLATION
1.Use special tools to install the bearing.

  • Installer cap (MD998812)
  • Installer-200 (MD998814)
  • Installer adapter (42) (MD998820)
2.Press the input shaft with a press and install the bearing.

>>G<< 3RD GEAR SLEEVE INSTALLATION
1.Use special tools to install the 3RD gear sleeve.

  • Installer cap (MD998812)
  • Installer-200 (MD998814)
  • Installer adapter (40) (MD998819)
2.Press the input shaft with a press and install the 3RD gear sleeve.