DISASSEMBLY AND REASSEMBLY







Disassembly steps

>>G<<
1.
Shaft snap ring
<<A>>
>>F<<
2.
5th gear
<<B>>
>>E<<
3.
Radial ball bearing
<<B>>
>>E<<
4.
1st gear sub-assembly


5.
1st gear thrust washer


6.
Straight pin


7.
Needle roller bearing


8.
D spacer


9.
Synchronizer ring set No.1

>>D<<
10.
Shaft snap ring
<<C>>
>>C<<
11.
Reverse gear
<<C>>
>>C<<
12.
Synchronizer shifting key No.1
<<C>>
>>C<<
13.
Compression spring
<<C>>
>>C<<
14.
Transmission clutch No.1 hub
<<C>>
>>C<<
15.
Synchronizer ring set No.1
<<C>>
>>C<<
16.
2nd gear sub-assembly


17.
Needle roller bearing

>>B<<
18.
Shaft snap ring
<<D>>
>>A<<
19.
Transmission hub sleeve No.2
<<D>>
>>A<<
20.
Synchronizer shifting key No.2
<<D>>
>>A<<
21.
Compression spring
<<D>>
>>A<<
22.
Transmission clutch No.2 hub
<<D>>
>>A<<
23.
Synchronizer ring No.2
<<D>>
>>A<<
24.
3rd gear sub-assembly


25.
Needle roller bearing


26.
Output shaft

INSPECTION BEFORE DISASSEMBLY



THRUST CLEARANCE FOR EACH GEAR



Inspect the thrust clearance of each gear.
Gear
Standard value mm
Limit mm
1st
0.20 - 0.45
0.45
2nd
0.10 - 0.25
0.25
3rd
0.10 - 0.25
0.25

RADIAL CLEARANCE FOR EACH GEAR



1.Fix the output shaft by a vice.
2.Inspect the radial clearance of each gear.
Gear
Standard value mm
Limit mm
1st
0.020 - 0.073
0.073
2nd
0.015 - 0.068
0.068
3rd
0.015 - 0.068
0.068

DISASSEMBLY SERVICE POINTS



<<A>> 5TH GEAR REMOVAL



Using special tool Bearing remover (MD998801), support the 5th gear and remove it.

<<B>> RADIAL BALL BEARING / 1ST GEAR SUB-ASSEMBLY REMOVAL



Using special tool Bearing remover (MD998801), support the 1st gear sub-assembly and remove the radial ball bearing and the 1st gear sub-assembly.

<<C>> REVERSE GEAR / SYNCHRONIZER SHIFTING KEY No.1 / COMPRESSION SPRING / TRANSMISSION CLUTCH No.1 HUB / SYNCHRONIZER RING SET No.1 / 2ND GEAR SUB-ASSEMBLY REMOVAL



Using special tool Bearing remover (MD998801), support the 2nd gear sub-assembly and remove the reverse gear, synchronizer shifting key No.1, compression spring, the transmission clutch No.1 hub, synchronizer ring set No.1 and the 2nd gear sub-assembly.

<<D>> TRANSMISSION CLUTCH HUB No.2 / SYNCHRONIZER SHIFTING KEY No.2 / COMPRESSION SPRING / TRANSMISSION HUB SLEEVE No.2 / SYNCHRONIZER RING No.2 / 3RD GEAR SUB-ASSEMBLY REMOVAL



Using special tool Bearing remover (MD998801), support the 3rd gear sub-assembly and remove the transmission clutch hub No.2, synchronizer shifting key No.2, compression spring, the transmission hub sleeve No.2, synchronizer ring No.2 and the 3rd gear sub-assembly.

REASSEMBLY SERVICE POINTS



>>A<< TRANSMISSION CLUTCH HUB No. 2 / SYNCHRONIZER SHIFTING KEY No. 2 / COMPRESSION SPRING / TRANSMISSION HUB SLEEVE No. 2 / SYNCHRONIZER RING No. 2 / 3RD GEAR SUB-ASSEMBLY INSTALLATION



1.Check the installation direction of the transmission clutch hub No. 2, and put it on the output shaft.

2.Using special tools to install the transmission clutch hub No. 2, synchronizer shifting key No. 2, compression spring, the transmission hub sleeve No. 2, synchronizer ring No. 2 and the 3rd gear sub-assembly.

  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer adapter (48) (MD998823)

3.Confirm the thrust clearance of the 3rd gear sub-assembly is within the standard value.
Standard value: 0.10 - 0.25 mm
Limit: 0.25 mm

>>B<< SHAFT SNAP RING INSTALLATION



1.Select a shaft snap ring to secure the standard clearance between the transmission clutch hub No.2 and the output shaft.
Standard value: 0 - 0.1 mm
2.Install the selected snap ring.

>>C<< REVERSE GEAR / SYNCHRONIZER SHIFTING KEY No. 1 / COMPRESSION SPRING / TRANSMISSION CLUTCH No. 1 HUB / SYNCHRONIZER RING SET No. 1 / 2ND GEAR SUB-ASSEMBLY INSTALLATION



1.Check the installation direction of the reverse gear, and put it on the output shaft.

2.Using special tools to install the reverse gear, synchronizer shifting key No. 1, compression spring, the transmission clutch No. 1 hub, synchronizer ring set No. 1 and the 2nd gear sub-assembly.

  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer-200 (MD998814)
  • Installer adapter (48) (MD998823)

3.Confirm the thrust clearance of the 2nd gear sub-assembly is within the standard value.
Standard value: 0.10 - 0.25 mm
Limit: 0.25 mm

>>D<< SHAFT SNAP RING INSTALLATION



1.Select a snap ring to secure the standard clearance between the transmission clutch No. 1 hub and the output shaft.
Standard value: 0 - 0.1 mm
2.Install the selected snap ring.

>>E<< RADIAL BALL BEARING / 1ST GEAR SUB-ASSEMBLY INSTALLATION



1.Check the installation direction of the radial ball bearing, and put it on the output shaft.

2.
caution Never push on the sealing area when installing.
Using special tools to install the radial ball bearing and the 1st gear sub-assembly.

  • Installer cap (MD998812)
  • Installer-200 (MD998814)
  • Installer adapter (48) (MD998823)

3.Confirm the thrust clearance of the 1st gear sub-assembly is within the standard value.
Standard value: 0.20 - 0.45 mm
Limit: 0.45 mm

>>F<< 5TH GEAR INSTALLATION



1.Check the installation direction of the 5th gear, and put it on the output shaft.

2.Using special tools to install the 5th gear.

  • Installer cap (MD998812)
  • Installer-200 (MD998814)
  • Installer adapter (48) (MD998823)

>>G<< SHAFT SNAP RING INSTALLATION



1.Select a shaft snap ring to secure the standard clearance between the 5th gear and the output shaft
Standard value: 0 - 0.1 mm
2.Install the selected snap ring.





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