FREE WHEEL CLUTCH DISASSEMBLY AND REASSEMBLY <VEHICLES WITH FREEWHEEL CLUTCH>







Disassembly steps


1.
Main shaft assembly
<<A>>
>>F<<
2.
Main shaft
<<A>>
>>F<<
3.
Bearing


4.
Clutch sleeve

>>E<<
5.
Spacer

>>D<<
6.
Spring pin


7.
Shift fork


8.
Shift rod


9.
Bushing

>>C<<
10.
Oil seal
<<B>>
>>B<<
11.
Clutch gear
<<B>>
>>B<<
12.
Bearing

>>A<<
13.
Oil seal


14.
Housing tube

DISASSEMBLY SERVICE POINTS



<<A>> MAIN SHAFT/BEARING REMOVAL



1.After special tool bearing remover (MB990560) has been installed as shown, tighten the nut of special tool until portion "A" of special tool touches the bearing outer race.
2.
caution Do not allow the main shaft to drop.
Press out the main shaft from the bearing.

<<B>> CLUTCH GEAR/BEARING REMOVAL



1.Use special tool lower arm bush arbour (MB991318) to remove the clutch gear and bearing together.
note Apply rag inside of the clutch gear so as not to damage spline part.

2.Using a press and special tool bearing remover (MB990560), 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 ball joint remover and installer A (MB990799) 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.

2.
caution Place the special tool against the outer race of the bearing.
Use special tool rear suspension housing base (MB990890 or MB990891) to press-fit the bearing to the side of the clutch housing.

>>C<<OIL SEAL INSTALLATION



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

  • Installer adapter (MB990926)
  • 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.
Spacer type
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/MAIN SHAFT INSTALLATION



Press-fit the bearing to the shoulder of the main shaft.