DISASSEMBLY AND REASSEMBLY

			Disassembly steps
<<A>>		1.	Bearing
		2.	Snap ring
<<B>>		3.	Bearing
<<C>>		4.	Reverse synchronizer sleeve, reverse synchronizer hub, reverse speed gear and 1ST speed gear
		5.	Synchronizer key
		6.	Reverse synchronizer sleeve
		7.	Reverse synchronizer hub
		8.	Synchronizer ring
		9.	Reverse speed gear
		10.	Needle bearing
		11.	Reverse gear sleeve
		12.	1ST speed gear
		13.	Needle bearing
		14.	Synchronizer inner ring
		15.	Synchronizer cone
		16.	Synchronizer outer ring
<<D>>		17.	1ST and 2ND synchronizer hub, 1ST and 2ND synchronizer sleeve and 2ND speed gear
		18.	Synchronizer key
		19.	1ST and 2ND synchronizer sleeve
		20.	1ST gear sleeve
		21.	1ST and 2ND synchronizer hub
		22.	Synchronizer outer ring
		23.	Synchronizer cone
		24.	Synchronizer inner ring
		25.	2ND speed gear
		26.	Needle bearing
		27.	Oil guide
		28.	Countershaft
			Reassembly steps
		28.	Countershaft
		27.	Oil guide
		26.	Needle bearing
		25.	2ND speed gear
		24.	Synchronizer inner ring
		23.	Synchronizer cone
		22.	Synchronizer outer ring
	>>A<<	21.	1ST and 2ND synchronizer hub
	>>B<<	20.	1ST gear sleeve
	>>C<<	19.	1ST and 2ND synchronizer sleeve
		18.	Synchronizer key
		16.	Synchronizer outer ring
		15.	Synchronizer cone
		14.	Synchronizer inner ring
		13.	Needle bearing
		12.	1ST speed gear
	>>D<<	11.	Reverse gear sleeve
		10.	Needle bearing
		9.	Reverse speed gear
		8.	Synchronizer ring
	>>E<<	7.	Reverse synchronizer hub
	>>F<<	6.	Reverse synchronizer sleeve
		5.	Synchronizer key
	>>G<<	3.	Bearing
	>>H<<	2.	Snap ring
	>>I<<	1.	Bearing

DISASSEMBLY SERVICE POINTS

<<A>> BEARING REMOVAL

1.Use special tool remover (MD998801) to support the bearing.

2.Press the countershaft with a press and remove the bearing.

<<B>> BEARING REMOVAL

1.Use special tools to support the bearing.

Remover (MD998801)
Bearing installer (MD998322)

2.Press the countershaft with a press and remove the bearing.

<<C>> REVERSE SYNCHRONIZER SLEEVE, REVERSE SYNCHRONIZER HUB, REVERSE SPEED GEAR AND 1ST SPEED GEAR REMOVAL

1.Use special tool remover (MD998801) to support the reverse synchronizer sleeve, reverse synchronizer hub, reverse speed gear and 1ST speed gear.

2.Press the countershaft with a press and remove the reverse synchronizer sleeve, reverse synchronizer hub, reverse speed gear and 1ST speed gear.

<<D>> 1ST AND 2ND SYNCHRONIZER HUB, 1ST AND 2ND SYNCHRONIZER SLEEVE AND 2ND SPEED GEAR REMOVAL

1.Use special tool remover (MD998801) to support the 1ST and 2ND synchronizer hub, 1ST and 2ND synchronizer sleeve and 2ND speed gear.

2.Press the countershaft with a press and remove the 1ST and 2ND synchronizer hub, 1ST and 2ND synchronizer sleeve and 2ND speed gear.

REASSEMBLY SERVICE POINTS

>>A<< 1ST AND 2ND SYNCHRONIZER HUB INSTALLATION

1.The identification mark (2 mm-dia. circle) is stamped on the side of the 1st and 2nd synchronizer hubs. These identification marks should face rearwards when these hubs are inserted into the countershaft.

2.Use special tools to install the 1ST and 2ND synchronizer hub.

Installer cap (MD998812)
Installer-200 (MD998814)
Installer adapter (50) (MD998824)

3.Press the countershaft with a press and install the 1ST and 2ND synchronizer hub.

>>B<< 1ST GEAR SLEEVE INSTALLATION

1.Use special tools to install the 1ST gear sleeve.

Installer cap (MD998812)
Installer-200 (MD998814)
Installer adapter (44) (MD998821)

2.Press the countershaft with a press and install the 1ST gear sleeve.

>>C<< 1ST AND 2ND SYNCHRONIZER SLEEVE INSTALLATION

The identification groove on the 1st and 2nd synchronizer sleeves should face towards the clutch housing when the sleeves are inserted into the countershaft.

>>D<< REVERSE GEAR SLEEVE INSTALLATION

1.Use special tools to install the reverse gear sleeve.

Installer cap (MD998812)
Installer-200 (MD998814)
Installer adapter (42) (MD998820)

2.Press the countershaft with a press and install the reverse gear sleeve.

>>E<< REVERSE SYNCHRONIZER HUB INSTALLATION

1.Use special tools to install the reverse synchronizer hub.

Installer cap (MD998812)
Installer-200 (MD998814)
Installer adapter (40) (MD998819)

2.Press the countershaft with a press and install the reverse synchronizer hub.

>>F<< REVERSE SYNCHRONIZER SLEEVE INSTALLATION

The identification groove on the reverse synchronizer sleeve should face towards the clutch housing when the sleeve is inserted into the countershaft.

>>G<< BEARING INSTALLATION

1.Use special tools to install the bearing.

Installer cap (MD998812)
Installer-200 (MD998814)
Installer adapter (40) (MD998819)

2.Press the countershaft with a press and install the bearing.

>>H<< SNAP RING INSTALLATION

1.Install the thickest snap ring that can be fitted in the snap ring groove of the countershaft.

2.Make sure that the bearing end play meets the standard value.
Standard value: - 0.01 - 0.09 mm

>>I<< BEARING INSTALLATION

1.Check the installation direction of the bearing, and put it on the countershaft.
2.Use special tools to install the bearing.

Installer cap (MD998812)
Installer-200 (MD998814)
Installer adapter (46) (MD998822)

3.Press the countershaft with a press and install the bearing.