DISASSEMBLY AND REASSEMBLY

Disassembly steps 1. 1st speed gear 2. Needle bearing <<A>> >>E<< 3. Bearing sleeve <<A>> 4. Synchronizer cone <<A>> 5. Synchronizer inner ring <<A>> 6. Synchronizer outer ring <<A>> >>D<< 7. 1st-2nd synchronizer sleeve <<A>> >>D<< 8. 1st-2nd synchronizer hub <<A>> 9. Synchronizer outer spring <<A>> 10. Synchronizer key <<A>> 11. Synchronizer outer ring <<A>> 12. Synchronizer inner ring <<A>> 13. Synchronizer cone <<A>> 14. 2nd speed gear 15. Needle bearing >>C<< 16. Snap ring <<B>> >>A<< 17. 3rd-4th synchronizer sleeve <<B>> >>A<< 18. 3rd-4th synchronizer hub <<B>> >>B<< 19. Synchronizer spring <<B>> >>B<< 20. Synchronizer key <<B>> 21. Synchronizer ring <<B>> 22. Needle bearing <<B>> 23. 3rd speed gear 24. Main shaft

1.Support the 2nd speed gear on the special tool Bearing remove (MD998917) as illustrated. 2.Remove the bearing sleeve, synchronizer cone, synchronizer inner ring, synchronizer outer ring, 1st-2nd synchronizer hub, synchronizer outer spring, synchronizer key, 1st-2nd synchronizer sleeve and 2nd speed gear using a press.

1.Support the 3rd speed gear on the special tool Bearing remove (MD998917) as illustrated. 2.Remove the 3rd-4th synchronizer sleeve, 3rd-4th synchronizer hub, synchronizer spring, synchronizer key, synchronizer ring, needle bearing and 3rd speed gear 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 3rd-4th synchronizer hub and 3rd-4th synchronizer 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 1st-2nd synchronizer hub and 1st-2nd synchronizer 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)