Input Shaft

Input Shaft





Special Tool(s)





Material

Disassembly

CAUTION: The inner synchronizer ring and the synchronizer cone must be handled very carefully.

NOTE: If there any new installation of bearings, shafts or the transaxle housings is necessary, the transaxle must be shimmed.





1. CAUTION: The roller bearing is damaged when it is pressed off using the special tool and cannot be reused.

Using the special tool, remove the clutch housing roller bearing.





2. CAUTION: The roller bearing is damaged when it is pressed off using the special tool and cannot be reused.

Using the special tool, remove the transaxle housing roller bearing.





3. CAUTION: Components may be damaged when pressed off using the special tool or an equivalent tool.

Using the special tool, press off the fifth gear wheel.
1. Discard the snap ring.
2. Press off the fifth gear wheel.





4. Remove the fourth gear wheel.
1. Remove the fourth gear wheel.
2. Remove the needle roller bearing.
3. Remove the synchronizer ring.





5. Remove the third and fourth gear synchronizer assembly.
1. Discard the snap ring.
2. Remove the synchronizer assembly.





6. NOTE: Take care when pulling the selector ring off the gear synchronizer hub. The detent balls are spring-loaded.

Disassemble the third and fourth gear synchronizer.
1. Remove the selector ring.
2. Remove the gear synchronizer hub.
3. Remove the compression springs.
4. Remove the blocker bars.
5. Remove the detent balls.





7. Remove the third gear wheel.
1. Remove the synchronizer ring.
2. Remove the gear wheel.
3. Remove the needle roller bearing.

Assembly

1. NOTE: Do not oil taper roller bearings which are to be used again. New taper roller bearings can be installed without any treatment.

NOTE: Using a suitable press, install the gear wheels.

Carefully clean and check all sliding parts and lubricate them with clean manual transmission fluid before assembly.





2. Using a length of suitable tube, install the clutch housing roller bearing.





3. NOTE: Do not oil taper roller bearings which are to be used again. New taper roller bearings can be installed without any treatment.

Install the third gear wheel.
1. Install the needle roller bearing.
2. Install the gear wheel.
3. Install the synchronizer ring.





4. Assemble the third and fourth gear synchronizer.
1. Install the compression springs.
2. Install the synchronizer bar and detent balls by pressing against the spring pressure.
3. Install the selector ring the right way round and slide it on.





5. NOTE: Install the synchronizer hub with the large collar facing outwards and the annular groove facing the small collar.
Installation position of the synchronizer assembly shown.





6. NOTE: Install the synchronizer hub with the large collar facing outwards.

NOTE: Install a new snap ring.

NOTE: The snap ring thickness is 2.5 mm. Install the complete third and fourth gear synchronizer assembly.

1. Install the synchronizer assembly.
2. Install the snap ring.





7. Install the fourth gear wheel.
1. Install the synchronizer ring.
2. Install the needle roller bearing.
3. Install the gear wheel.





8. NOTE: Install a new snap ring.

Press on the fifth gear wheel.
- Using a length of suitable tube, press on the fifth gear wheel.
- Install the snap ring.





9. Using a length of suitable tube, install the transaxle housing roller bearing.