DISASSEMBLY AND REASSEMBLY






1.
Shaft snap ring


2.
Radial ball bearing


3.
3rd gear thrust washer


4.
Ball


5.
3rd gear sub-assembly


6.
Spacer


7.
Needle roller bearing


8.
Synchronizer ring set #1


9.
Shaft snap ring


10.
3rd-4th hub sleeve


11.
Synchronizer ring set #4


12.
4th gear sub-assembly


13.
Needle roller bearing


14.
Spacer


15.
Shaft snap ring


16.
2nd gear hearing inner race


17.
2nd gear


18.
Needle roller bearing


19.
Synchronizer ring set #1


20.
Ball


21.
1st-2nd hub sleeve


22.
Synchronizer ring set #1


23.
1st gear


24.
Needle roller bearing


25.
Shaft snap ring


26.
Cylindrical roller bearing

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 thrust washer.
4.Remove the ball.

5.Remove the 3rd gear sub-assembly.

6.Remove the spacer, needle roller bearing and synchronizer ring set #1.

7.Remove the shaft snap ring.

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.

9.Remove the needle roller bearing.

10.Remove the spacer.

11.Remove the shaft snap ring.

12.Remove the 2nd gear bearing inner race.

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

14.Remove the synchronizer ring set #1.

15.Remove the ball.

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.

18.Remove the shaft snap ring.

19.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 #1.

3.Install the 1st gear and needle roller bearing to output shaft #1.



4.Install the synchronizer ring set #1 to 1st gear.
note Apply the gear oil sufficiently on the sliding surface.

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.

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.
Install the 1st-2nd hub sleeve to the output shaft #1 in the direction as shown in the illustration.

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.

8.Insert the ball to the output shaft #1.
note Do not forget to attach the ball.

9.Install the synchronizer ring set #1 to 1st-2nd hub sleeve.

10.Insert the 2nd gear and needle roller bearing to the output shaft #1.

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

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

13.Insert the spacer to the output shaft #1.

14.Insert the needle roller bearing to the output shaft #1.

15.Insert the 4th gear sub-assembly and synchronizer ring set #4 to the output shaft #1.

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.

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.
Set the 3rd-4th hub sleeve to the output shaft #1 in the direction as shown in the illustration.

18.Using special tools, install the 3rd-4th hub sleeve.

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

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

20.Insert the synchronizer ring set #1, needle roller bearing and spacer to the 3rd-4th hub sleeve.

21.Insert the 3rd gear sub-assembly to the output shaft #1.
22.Answer the ball
23.Answer the 3rd gear thrust washer

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

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

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