Mainshaft: Service and Repair

NOTE: The 3rd/4th and 5th synchro hubs are installed with a press. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. The 3rd/4th and 5th synchro hubs, however, should be installed with a press before lubricating them.

TOOLS REQUIRED
- 07746-0030400 Attachment, 35 mm I.D.
- 07746-0030100 Driver, 40 mm I.D.
- 07746-0030300 Attachment, 30 mm I.D.
- Or Equivalent

REMOVAL
1. Remove the interlock guide bolt from under the clutch housing.





2. Remove the shift arm B attaching bolt.





3. Remove the mainshaft and countershaft assemblies with the shift fork from the clutch housing.

NOTE: Before removing the mainshaft and countershaft assemblies, tape the mainshaft spline to protect it.

DISASSEMBLE





1. Remove the ball bearing using a bearing puller as shown.

CAUTION: Remove the synchro hubs using a press and steel blocks as shown. Use of a jaw-type puller can cause damage to the gear teeth.





2. Support 4th gear on steel blocks as shown and press the shaft out of the 5th synchro hub.





3. Support the 3rd gear on steel blocks as shown, and press the shaft out of the 3rd/4th synchro hub.

INSPECTION
Inspect mainshaft Testing and Inspection.

ASSEMBLE

CAUTION: When installing the 3rd/4th and 5th synchro hubs, support the shaft on steel blocks, and install the synchro hubs using a press.





1. Support 2nd gear on steel blocks as shown, then install the 3rd/4th synchro hub using the special tools and a press as shown.





2. Install the 3rd/4th synchro sleeve by aligning the stops of the 3rd/4th synchro sleeve and hub.

NOTE: After installing, inspect the operation of the 3rd/4th synchro hub set.





3. Install the 5th synchro hub using the special tools and a press as shown.





4. Install the ball bearing using the special tools and a press as shown.

NOTE: Install the ball bearing with the tapered and facing down.