DISASSEMBLY AND REASSEMBLY

M12202000061ENG0000010000

			Disassembly steps
	>>J<<	1.	Snap ring
	>>I<<	2.	3rd-4th speed synchronizer sleeve
<<A>>	>>H<<	3.	3rd-4th speed synchronizer hub
		4.	Synchronizer spring
	>>A<<	5.	Synchronizer outer ring
	>>A<<	6.	Synchronizer cone
	>>A<<	7.	Synchronizer inner ring
		8.	3rd speed gear
		9.	Needle bearing
<<B>>	>>G<<	10	5th speed gear
<<B>>	>>F<<	11	Ball bearing
<<B>>	>>E<<	12.	Bearing sleeve
<<B>>		13.	1st speed gear
		14.	Needle bearing
		15.	Synchronizer inner ring
		16.	Synchronizer cone
		17.	Synchronizer outer ring
	>>D<<	18.	Synchronizer spring
	>>C<<	19.	1st-2nd speed synchronizer sleeve
<<C>>	>>B<<	20.	1st-2nd speed synchronizer hub
		21.	Synchronizer spring
	>>A<<	22.	Synchronizer outer ring
	>>A<<	23.	Synchronizer cone
	>>A<<	24.	Synchronizer inner ring
<<C>>		25.	2nd speed gear
		26.	Needle bearing
		27.	Main shaft

DISASSEMBLY SERVICE POINTS

Using special tool Bearing remover (MD998917), remove the 3rd-4th speed synchronizer hub to the main shaft.

Using special tool Bearing remover (MD998917), remove the 5th speed gear, ball bearing, bearing sleeve and 1st speed gear to the main shaft.

Using special tool Bearing remover (MD998917), remove the 1st-2nd speed synchronizer hub and 2nd speed gear to the main shaft.

Assemble the inner ring, outer ring and cone and set the assembly to the synchronizer hub.

1. Assemble the inner ring, outer ring and cone and set the assembly to the synchronizer hub.

2. Using special tools to install the 1st-2nd speed synchronizer hub to the main shaft.

1. Check that the 1st-2nd speed synchronizer sleeve is in the correct direction for installation.

2. Install the sleeve with its projections aligned with the deep grooves in the synchronizer hub.

Install the synchronizer spring onto the synchronizer ring so that the spring is settled as illustrated.

Using special tools to install the bearing sleeve to the main shaft.

Using special tools to install the ball bearing to the main shaft.

Using special tools to install the 5th speed gear to the main shaft.

1. Check that the 3rd-4th speed synchronizer hub is in the correct direction for installation.

2. Using special tools to install the 3rd-4th speed synchronizer hub to the main shaft.

1. Check that the 3rd-4th speed synchronizer sleeve is in the correct direction for installation.

2. Install the sleeve with its projections aligned with the deep grooves in the synchronizer hub.

Select a snap ring which will make the 3rd-4th speed synchronizer hub end play equal to the standard value.
Standard value: 0 - 0.08 mm