Mainshaft Reassembly

Mainshaft Reassembly

Mainshaft:

Special Tools Required
^ Driver handle 07746-0030100
^ Attachment, 30 mm I.D. 07746-0030300

NOTE: Refer to the Exploded View, as needed, during this procedure.

1. Support 2nd gear (A) on steel blocks, then install the ball bearing (B) using the driver handle (C), 30 mm I.D. attachment (D), and a press as shown.

2. Install the 39 x 44 x 26 mm needle bearing, 6th gear, synchro ring, and synchro spring.
3. Install the 5th/6th synchro hub (A) and the 5th/6th synchro sleeve (B) by aligning the stops (C).

4. Press the 5th/6th synchro hub using the driver handle (A) as shown. After installing, check the operation of the 5th/6th synchro hub and 5th/6th synchro sleeve.

5. Install the synchro spring, synchro ring, 42 x 47 x 30.5 mm needle bearings, 5th gear, distance collar, and 4th gear.
6. '00-03 models: Install the double cone synchro (A) and synchro ring (B).

7. '04-08 models: Install the synchro ring (A) and synchro spring (B).

8. Install the 3rd/4th synchro hub (A) and the 3rd/4th synchro sleeve (B) by aligning the stops (C).

9. Press the 3rd/4th synchro hub using the driver handle (A) as shown. After installing, check the operation of the 3rd/4th synchro hub and sleeve.

10. '00-03 models: Install the synchro spring (A) and double cone synchro (B).

11. '04-08 models: Install the synchro spring (A) and synchro ring (B).

12. Install the distance collar (A), the 35 x 40 x 35 mm needle bearing (B), and 3rd gear (C).

13. Install the angular ball bearing (A) with the thin edge of the outer race facing 3rd gear (B). Use the driver handle (C) and a press.