M/T Mainshaft Reassembly

M/T Mainshaft Reassembly

Exploded View '00-03 models





Exploded View '04-09 models





Special Tools Required

- Inner driver handle, 40 mm 07746-0030100
- Inner bearing driver attachment, 30 mm 07746-0030300
NOTE: Refer to the Exploded View, as needed, during this procedure.

1. Support 2nd gear (A) on steel blocks, then press on the ball bearing (B) using the 40 mm inner driver handle (C), 30 mm inner bearing driver attachment (D), and a press as shown.
NOTE: The thin edge of the outer race faces 6th gear.

2. Install the 39 x 44 x 26 mm needle bearing, 6th gear, the synchro ring, and the synchro spring.






3. Install the 5th/6th synchro hub (A) and the 5th/6th synchro sleeve (B) by aligning the stops (C).






4. Press on the 5th/6th synchro hub using the 40 mm inner driver handle (A) as shown. After installing, check the operation of the 5th/6th synchro hub and the 5th/6th synchro sleeve.

5. Install the synchro spring, the synchro ring, the 42 x 47 x 30.5 mm needle bearings, 5th gear, the 4th/5th gear distance collar, and 4th gear.






6. '00-03 models: Install the double cone synchro (A) and the synchro ring (B).






7. '04-09 models: Install the synchro ring (A) and the 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 on the 3rd/4th synchro hub using the 40 mm inner driver handle (A) as shown. After installing, check the operation of the 3rd/4th synchro hub and the 3rd/4th synchro sleeve.






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






11. '04-09 models: Install the synchro spring (A) and the synchro ring (B).






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






13. Press on the angular ball bearing (A) using the 40 mm inner driver handle (B) with the thin edge of the outer race facing 3rd gear (C).