Disassembly
Warning! Remove the synchronizer hubs using a press and steel bars, as shown in the figure. If you use a puller with grips, you can break the gear teeth.
1. Mount the 5th gear on steel blocks and press the output shaft out of the 5th synchronizer hub as shown.
2. In the same way, install the 3rd gear on steel blocks and press the output shaft out of the 3rd/4th gear synchronizer hub as shown.
Examination
1. Check the surface of the gears and bearings for wear and damage, then take measurements on the output shaft at points A, B and C.
Standard: | Limit: | |
A (ball bearing surface): | 27.987-28.000 mm | 27.94 mm |
IN (needle bearing surface): | 37.984-38.000 mm | 37.93 mm |
WITH (ball bearing surface): | 27.977-27.990 mm | 27.94 mm |
If any part of the output shaft is less than the specified limits, replace it with a new one.
2. Check for runout.
- Standard: max. 0.02mm
- Limit: 0.05mm
Note: Place the output shaft with both ends on supports as shown in the figure.
If the runout exceeds the limit, replace the output shaft with a new one.
Assembly
Note: When assembling, follow the index (see above).
1. Install the 2nd gear on the steel bars as shown in the figure, then use the special tool to install the 3rd/4th gear synchronizer hub and press in as shown in the figure.
2. Using the special tool, install the 5th gear synchronizer hub and press it in as shown in the figure.
3. Using the special tool, install the ball bearing and press it in as shown.