Disassembly
Caution! Remove the synchronizer hubs using a press and steel bars as shown in the figure. If you use a puller with jaws, you may break the gear teeth.
1. Place the 5th gear on steel blocks and press the secondary shaft out of the 5th gear synchronizer hub as shown in the figure.
2. Similarly, install the 3rd gear pinion on steel blocks and press out the secondary shaft from the 3rd/4th gear synchronizer hub, as shown in the figure.
Examination
1. Check the gear and bearing surfaces for wear and damage, then take measurements on the secondary shaft at points A, B and C.
| Standard: | Limit: | |
| A(Ball bearing surface): | 27,987-28,000 mm | 27.94 mm |
| B(needle bearing surface): | 37,984-38,000 mm | 37.93 mm |
| C(ball bearing surface): | 27,977-27,990 mm | 27.94 mm |
If any part of the secondary shaft is less than the specified limits, replace it with a new one.
2. Check the runout.
- Standard: max 0.02mm
- Limit: 0.05 mm
Note: Place the secondary shaft with both ends on the supports as shown in the figure.
If the runout exceeds the limit, replace the secondary shaft with a new one.
Assembly
Note: When assembling, please refer to the indicator (see above).
1. Install the 2nd gear pinion on the steel blocks as shown in the figure, then use the special tool to install the 3rd/4th gear synchronizer hub and press it in as shown in the figure.
2. Using a special tool, install the 5th gear synchronizer hub and press it in as shown in the figure.
3. Using a special tool, install the ball bearing and press it in as shown in the figure.
