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1.Remove the shaft snap ring.
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2.Using special tool Bearing remover (MD998917), support the radial ball bearing and remove
the radial ball bearing. 3.Remove the 3rd gear thrust washer. 4.Remove the ball.
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5.Remove the 3rd gear sub-assembly.
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6.Remove the spacer, needle roller bearing and synchronizer ring set #1.
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7.Remove the shaft snap ring.
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8.Using special tool Bearing remover (MD998917), support the 4th gear sub-assembly and remove
the 3rd-4th hub sleeve, synchronizer ring set #4 and 4th gear sub-assembly.
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9.Remove the needle roller bearing.
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11.Remove the shaft snap ring.
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12.Remove the 2nd gear bearing inner race.
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13.Remove the 2nd gear and needle roller bearing.
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14.Remove the synchronizer ring set #1.
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16.Using special tool Bearing remover (MD998917), support the 1st gear and remove the 1st-2nd
hub sleeve, synchronizer ring set #1 and 1st gear. 17.Remove the needle roller bearing.
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18.Remove the shaft snap ring.
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19.Using special tool Rear axle shaft bearing installer (MB990560), support the cylindrical
roller bearing and remove the cylindrical roller bearing.
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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.
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2.Install the shaft snap ring to output shaft #1.
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3.Install the 1st gear and needle roller bearing to output shaft #1.
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4.Install the synchronizer ring set #1 to 1st gear.
note |
Apply the gear oil sufficiently on the sliding surface.
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5.As shown in the illustration, set the 1st-2nd hub sleeve.
note |
- Apply gear oil to the caulked area between the sleeve and the hub.
- After installation, confirm the sleeve and the hub slide smoothly.
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6.
caution |
- Pay attention to the direction of inserting the 1st-2nd hub sleeve.
- 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.
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Install the 1st-2nd hub sleeve to the output shaft #1 in the direction as shown
in the illustration.
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7.Using special tools, install the 1st-2nd hub sleeve.
- Installer cap (MD998812)
- Installer 200 (MD998814)
- Installer adapter (MD998824)
note |
Install 1st-2nd hub sleeve securely into the stopper of the output shaft #1.
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8.Insert the ball to the output shaft #1.
note |
Do not forget to attach the ball.
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9.Install the synchronizer ring set #1 to 1st-2nd hub sleeve.
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10.Insert the 2nd gear and needle roller bearing to the output shaft #1.
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11.Fit the ball into groove as shown in the illustration.
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12.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
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13.Insert the spacer to the output shaft #1.
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14.Insert the needle roller bearing to the output shaft #1.
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15.Insert the 4th gear sub-assembly and synchronizer ring set #4 to the output shaft #1.
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16.As shown in the illustration, set the 3rd-4th hub sleeve.
note |
- Apply gear oil to the caulked area between the sleeve and the hub.
- After installation, confirm the sleeve and the hub slide smoothly.
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17.
caution |
- Pay attention to the direction of inserting the 3rd-4th hub sleeve.
- 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.
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Set the 3rd-4th hub sleeve to the output shaft #1 in the direction as shown
in the illustration.
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18.Using special tools, install the 3rd-4th hub sleeve.
- Installer cap (MD998812)
- Installer 100 (MD998813)
- Installer adapter (MD998824)
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19.Select a shaft snap ring that allows distance of the thrust crevice of 3rd-4th hub to
fall within the standard value range. Standard value: 0 - 0.1 mm
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20.Insert the synchronizer ring set #1, needle roller bearing and spacer to the
3rd-4th hub sleeve.
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21.Insert the 3rd gear sub-assembly to the output shaft #1. 22.Answer the ball 23.Answer the 3rd gear thrust washer
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24.Using special tools, install the radial ball bearing.
- Installer cap (MD998812)
- Installer 100 (MD998813)
- Installer adapter (MD998824)
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25.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
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