DISASSEMBLY AND REASSEMBLY







Disassembly steps

>>E<<
1.
Snap ring
<<A>>
>>D<<
2.
Radial ball bearing


3.
4th gear sub-assembly


4.
Needle roller bearing


5.
Spacer

>>C<<
6.
Snap ring


7.
Synchronizer ring No.4
<<B>>
>>B<<
8.
Synchronizer clutch hub No.2
<<B>>
>>B<<
9.
Synchronizer hub sleeve No.2


10.
Synchromesh shifting key No.2


11.
Compression spring


12.
Synchronizer ring No.3
<<B>>

13.
3rd gear sub-assembly


14.
Needle roller bearing


15.
Snap ring
<<C>>
>>A<<
16.
Cylindrical roller bearing


17.
Input shaft

DISASSEMBLY SERVICE POINTS



<<A>> RADIAL BALL BEARING REMOVAL



Using special tool Bearing remover (MD998917), support the radial ball bearing and remove the radial ball bearing.

<<B>> SYNCHRONIZER HUB SLEEVE No.2, SYNCHRONIZER CLUTCH HUB No.2 AND 3RD GEAR SUB-ASSEMBLY REMOVAL



Using special tool Bearing remover (MD998917), support the 3rd gear sub- assembly and remove the 3rd gear sub- assembly, synchronizer hub sleeve No.2 and synchronizer clutch hub No.2.

<<C>> CYLINDRICAL ROLLER BEARING REMOVAL




Using special tool Rear axle shaft bearing remover (MB990560), support the cylindrical roller bearing and remove the cylindrical roller bearing.

REASSEMBLY SERVICE POINTS



>>A<< CYLINDRICAL ROLLER BEARING INSTALLATION



1.Check the installation direction of the cylindrical roller bearing

2.Using special tools to install the cylindrical roller bearing.

  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer adapter (MD998818)

>>B<< SYNCHRONIZER CLUTCH HUB No.2 AND SYNCHRONIZER HUB SLEEVE No.2 INSTALLATION



1.Before assembly, make sure that the hub and sleeve face the correct direction.
note
  • Apply gear oil to the caulked area between the sleeve and the hub.
  • After installation, confirm the sleeve and the hub slide smoothly.

2.Using special tools to install the synchronizer hub sleeve No.2 and synchronizer clutch hub No.2.

  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer adapter (MD998820)
  • Bearing remover (MD998917)

>>C<< SNAP RING INSTALLATION



Select a snap ring that allows distance of the thrust crevice of synchronizer hub No.2 to fall within the standard value range.
Standard value: 0 - 0.1 mm
note Try on snap rings in the decreasing order of thickness, and install the first one that fits into the input shaft.

>>D<< RADIAL BALL BEARING INSTALLATION



1.Before assembly, make sure that the radial ball bearing faces the correct direction.

2.Using special tools to install the radial ball bearing.

  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer adapter (MD998820)
  • Bearing remover (MD998917)

>>E<< SNAP RING INSTALLATION



Select a snap ring that allows distance of the thrust crevice of radial ball bearing to fall within the standard value range.
Standard value: 0 - 0.1 mm
note Try on snap rings in the decreasing order of thickness, and install the first one that fits into the input shaft.