DISASSEMBLY AND REASSEMBLY

Disassembly steps 1. 1st speed gear 2. Needle bearing <<A>> >>E<< 3. Bearing sleeve 4. Synchronizer inner ring 5. Synchronizer cone 6. Synchronizer outer ring >>D<< 7. 1st-2nd synchronizer sleeve 8. Synchronizer outer spring 9. Synchronizer key >>D<< 10. 1st-2nd synchronizer hub <<A>> 11. 2nd speed gear 12. Needle bearing 13. Needle bearing >>C<< 14. Snap ring >>A<< 15. 3rd-4th speed synchronizer sleeve 16. Synchronizer ring >>B<< 17. Synchronizer spring >>B<< 18. Synchronizer key <<B>> >>A<< 19. 3rd-4th speed synchronizer hub <<B>> 20. 3rd speed gear 21. Needle bearing 22. Mainshaft

1.Support the 2nd speed gear on the special tool Bearing remover (MD998917) as illustrated. 2.Remove the ball bearing sleeve using a press.

1.Support the 3rd speed gear on the special tool Bearing remover (MD998917) as illustrated. 2.Remove the 3rd speed gear with synchronizer hub and sleeve using a press.

1.Assemble the synchronizer hub and sleeve. Make sure that the hub and sleeve slide smoothly.

2.Use special tools to install the synchronizer hub and sleeve. Installer cap (MD998812) Installer adapter (44) (MD998821)

Install two synchronizer springs. When installing the springs, Make sure that steps of front and rear spring s are positioned on a synchronizer key, but not on the same key.

Select and install the snap ring so that the synchronizer hub end play may reach the standard value. Standard value: 0 - 0.08 mm

Assemble the synchronizer hub and sleeve. Make sure that the hub and sleeve slide smoothly.

Use special tools to install the bearing sleeve. Installer cap (MD998812) Installer-200 (MD998814) Installer adapter (40) (MD998819)