DISASSEMBLY AND REASSEMBLY






1.
Shaft snap ring


2.
Radial ball bearing


3.
3rd gear sub-assembly


4.
Needle roller bearing


5.
Spacer


6.
Shaft snap ring


7.
Synchronizer ring set No.1


8.
Transmission clutch hub No.2


9.
Transmission hub sleeve No.2


10.
Synchromesh shifting key No.1


11.
Ball


12.
Synchromesh shifting key spring


13.
Synchronizer ring set No.4


14.
4th gear sub-assembly


15.
Needle roller bearing


16.
Spacer


17.
Shaft snap ring


18.
2nd gear bearing inner race


19.
Needle roller bearing


20.
Ball


21.
2nd gear


22.
Synchronizer ring set No.1


23.
Transmission clutch hub No.1


24.
Transmission hub sleeve No.1


25.
Synchromesh shifting key No.1


26.
Ball


27.
Synchromesh shifting key spring


28.
Synchronizer ring set No.1


29.
1st gear


30.
Needle roller bearing


31.
Shaft snap ring


32.
Cylindrical roller bearing


33.
Output shaft No.1

DISASSEMBLY



1.Remove the shaft snap ring.

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

3.Remove the 3rd gear sub-assembly.

4.Remove the needle roller bearing and synchronizer ring set No.1.

5.Remove the shaft snap ring.

6.Using special tool Bearing remover (MD998917), support the 4th gear sub-assembly and remove the transmission hub sleeve No.2, ball, synchromesh shifting key spring, synchromesh shifting key No.1, transmission clutch hub No.2, synchronizer ring set No.4, synchronizer ring set No.1 and 4th gear sub-assembly.

7.Remove the needle roller bearing.

8.Remove the spacer.

9.Remove the shaft snap ring.

10.Remove the 2nd gear bearing inner race.

11.Remove the 2nd gear and needle roller bearing.

12.Remove the synchronizer ring set No.1.

13.Remove the ball.

14.Using special tool Bearing remover (MD998917), support the 1st gear and remove the synchromesh shifting key No.1, synchromesh shifting key spring, ball, transmission clutch hub No.1, transmission hub sleeve No.1, synchronizer ring set No.1 and 1st gear.
15.Remove the needle roller bearing.

16.Remove the shaft snap ring.

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

REASSEMBLY



1.Using special tools, install the cylindrical roller bearing.

  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer adapter (MD998820)
note Apply the gear oil sufficiently on the sliding surface.

2.Install the shaft snap ring to output shaft No.1.

3.Install the 1st gear and needle roller bearing to output shaft No.1.



4.Install the synchronizer ring set No.1 to 1st gear.
note Apply the gear oil sufficiently on the sliding surface.

5.As shown in the illustration, set the transmission hub sleeve No.1, synchromesh shifting key No.1, synchromesh shifting key spring, ball, transmission clutch hub No.1.
note
  • Apply gear oil to the caulked area between the sleeve and the hub.
  • After installation, confirm the sleeve and the hub slide smoothly.

6.
caution
  • Pay attention to the direction of inserting the transmission hub sleeve No.1.
  • During press fit, confirm correct positions of the hub and the synchronizer ring.
  • Check for smooth rotation of the gear after installation.
  • The synchronizer ring must not bind.
Install the transmission hub sleeve No.1, transmission clutch hub No.1 to the output shaft No.1 in the direction as shown in the illustration.

7.Using special tools, install the Transmission clutch hub No.1.

  • Installer cap (MD998812)
  • Installer-200 (MD998814)
  • Installer adapter (MD998824)
note Install transmission hub sleeve securely into the stopper of the output shaft No.1.

8.Insert the ball to the output shaft No.1.
note Do not forget to attach the ball.

9.Install the synchronizer ring set No.1 to 1st-2nd hub sleeve.

10.Insert the 2nd gear and needle roller bearing to the output shaft No.1.

11.Fit the ball into groove as shown in the illustration.

12.Insert the 2nd gear inner race to the output shaft No.1.

13.Select a shaft snap ring that allows distance of the thrust crevice of 2nd gear bearing inner race to fall within the standard value range.
Standard value: 0 - 0.1 mm

14.Insert the spacer to the output shaft No.1.

15.Insert the needle roller bearing to the output shaft No.1.

16.Insert the 4th gear sub-assembly and synchronizer ring set No.4 to the output shaft No.1.

17.As shown in the illustration, set the transmission hub sleeve No.2, transmission clutch hub No.2, synchromesh shifting key No.1, synchromesh shifting key spring, ball.
note
  • Apply gear oil to the caulked area between the sleeve and the hub.
  • After installation, confirm the sleeve and the hub slide smoothly.

18.
caution
  • Pay attention to the direction of inserting the transmission hub sleeve No.2.
  • During press fit, confirm correct positions of the hub and the synchronizer ring.
  • Check for smooth rotation of the gear after the installation.
  • The synchronizer ring must not bind.
Set the transmission hub sleeve No.2, transmission clutch hub No.2 to the output shaft No.1 in the direction as shown in the illustration.

19.Using special tools, install the transmission clutch hub No.2.

  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer adapter (MD998824)

20.Select a shaft snap ring that allows distance of the thrust crevice of transmission clutch hub No.2 to fall within the standard value range.
Standard value: 0 - 0.1 mm

21.Insert the synchronizer ring set No.1, needle roller bearing to the transmission clutch hub No.2.

22.Insert the 3rd gear sub-assembly to the output shaft No.1.

23.Using special tools, install the radial ball bearing.

  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer adapter (MD998824)

24.Select a shaft snap ring that allows distance of the thrust crevice of bearing to fall within the standard value range.
Standard value: 0 - 0.1 mm