DISASSEMBLY AND REASSEMBLY

			Disassembly steps
<<A>>	>>G<<	1.	Tapered roller bearing
<<A>>	>>F<<	2.	4th drive gear
		3.	Spacer
<<B>>	>>E<<	4.	3rd drive gear
<<B>>	>>D<<	5.	2nd gear
		6.	Needle roller bearing
		7.	2nd gear bush
		8.	Ball
		9.	Spacer
	>>D<<	10.	Synchronizer ring set No.2
	>>D<<	11.	Synchronizer inner ring No.2
	>>D<<	12.	Synchronizer middle ring No.2
	>>D<<	13.	Synchronizer outer ring No.2
<<C>>	>>C<<	14.	Reverse gear
		15.	Synchromesh shifting key No.1
		16.	Compression spring
<<C>>	>>C<<	17.	Synchronizer clutch hub No.1
	>>B<<	18.	Synchronizer ring set No.1
	>>B<<	19.	Synchronizer outer ring No.1
	>>B<<	20.	Synchronizer middle ring No.1
	>>B<<	21.	Synchronizer inner ring No.1
<<C>>	>>B<<	22.	1st gear
		23.	Needle roller bearing
<<D>>	>>A<<	24.	Tapered roller bearing
		25.	Output shaft

DISASSEMBLY SERVICE POINTS

<<A>> TAPERED ROLLER BEARING AND 4TH DRIVE GEAR REMOVAL

Using special tool Bearing remover (MD998917), support the 4th drive gear and remove the tapered roller bearing and 4th drive gear.

<<B>> 3RD DRIVE GEAR AND 2ND GEAR REMOVAL

Using special tool Bearing remover (MD998917), support the 2nd gear and remove the 3rd drive gear and 2nd gear.

<<C>> REVERSE GEAR, SYNCHRONIZER CLUTCH HUB No.1 AND 1ST GEAR REMOVAL

Using special tool Bearing remover (MD998917), support the 1st gear and remove the 1st gear, reverse gear and synchronizer clutch hub No.1.

<<D>> TAPERED ROLLER BEARING REMOVAL

Using special tools, support the tapered roller bearing and remove the tapered roller bearing.

Bearing remover (MD998917)
Bearing installer (MD998368)

note

Since special tool MD998917 holds the tapered roller bearing at the roller portion, the roller portion is broken when the tapered roller bearing is removed.

REASSEMBLY SERVICEPOINTS

>>A<< TAPERED ROLLER BEARING INSTALLATION

Using special tools, install the tapered roller bearing.

Installer cap (MD998812)
Installer-100 (MD998813)
Installer adapter (MD998820)

>>B<< SYNCHRONIZER RING SET No.1 (SYNCHRONIZER OUTER RING No.1, SYNCHRONIZER MIDDLE RING No.1, SYNCHRONIZER INNER RING No.1) AND 1ST GEAR INSTALLATION

caution

The rings of the synchronizer ring set No.1 and No.2 are dedicated to the 1st and 2nd gears. Be sure to install the right ring set to the right gear.

1.Make sure that the synchronizer outer ring of the synchronizer ring set No.1 is as shown.

2.Install the synchronizer ring set No.1 aligning the claws of the synchronizer middle ring to the positioning holes in the 1st gear.

note

Apply gear oil to the sufficiently on the sliding surface

>>C<< REVERSE GEAR AND SYNCHRONIZER CLUTCH HUB No.1 INSTALLATION

1.Install the reverse gear onto the synchronizer clutch hub No.1 in the illustrated direction.

note

Apply gear oil to the sufficiently on the sliding surface

2.Using special tools, install the synchronizer clutch hub No.1 and reverse gear.

Installer cap (MD998812)
Installer-200 (MD998814)
Installer adapter (MD998819)

3.After installation, confirm the 1st gear slides smoothly.

>>D<< SYNCHRONIZER RING SET No.2 (SYNCHRONIZER OUTER RING No.2, SYNCHRONIZER MIDDLE RING No.2, SYNCHRONIZER INNER RING No.2) AND 2ND GEAR INSTALLATION

caution

The rings of the synchronizer ring set No.1 and No.2 are dedicated to the 1st and 2nd gears. Be sure to install the right ring set to the right gear.

1.Make sure that the synchronizer outer ring of the synchronizer ring set No.2 is as shown.

2.Install the synchronizer ring set No.2 to the 2nd gear aligning the claws of the synchronizer middle ring to the positioning holes in the 2nd gear.

note

Apply gear oil to the sufficiently on the sliding surface

>>E<< 3RD DRIVE GEAR INSTALLATION

Using special tools, install the 3rd drive gear.

Installer cap (MD998812)
Installer-100 (MD998813)
Installer adapter (MD998819)

>>F<< 4TH DRIVE GEAR INSTALLATION

Using special tools, install the 4th drive gear.

Installer cap (MD998812)
Installer-100 (MD998813)
Installer adapter (MD998819)

>>G<< TAPERED ROLLER BEARING INSTALLATION

Using special tools, install the tapered roller bearing.

Installer cap (MD998812)
Installer-100 (MD998813)
Installer adapter (MD998819)