Input Shaft

Input Shaft





Special Tool(s)

Disassembly

CAUTION: The inner synchronizer ring and the synchronizer cone must be handled very carefully.

NOTE: If there any new installation of bearings, shafts or the transaxle housings is necessary, the transaxle must be shimmed.





1. CAUTION: The roller bearing is damaged when it is pressed off using the special tool and cannot be reused.

Using the special tool, remove the clutch housing roller bearing.





2. CAUTION: The roller bearing is damaged when it is pressed off using the special tool and cannot be reused.

Using the special tool, remove the transaxle housing roller bearing.





3. CAUTION: Components may be damaged when pressed off using the special tool or an equivalent tool.

Using the special tool, press off the fifth gear wheel.
1 Discard the snap ring.
2 Press off the fifth gear wheel.





4. Remove the fourth gear wheel.
1 Remove the fourth gear wheel.
2 Remove the needle roller bearing.
3 Remove the synchronizer ring.





5. Remove the third and fourth gear synchronizer assembly.
1 Discard the snap ring.
2 Remove the synchronizer assembly.





6. NOTE: Take care when pulling the selector ring off the gear synchronizer hub. The detent balls are spring-loaded.

Disassemble the third and fourth gear synchronizer.
1 Remove the selector ring.
2 Remove the gear synchronizer hub.
3 Remove the compression springs.
4 Remove the blacken bars.
5 Remove the detent balls.





7. Remove the third gear wheel.
1 Remove the synchronizer ring.
2 Remove the gear wheel.
3 Remove the needle roller bearing.

Assembly

1. NOTE: Do not oil taper roller bearings which are to be used again. New taper roller bearings can be installed without any treatment.

NOTE: Using a suitable press, install the gear wheels.

Carefully clean and check all sliding parts and lubricate them with clean manual transmission fluid before assembly.





2. Using a length of suitable tube, install the clutch housing roller bearing.





3. NOTE: Do not oil taper roller bearings which are to be used again. New taper roller bearings can be installed without any treatment.

Install the third gear wheel.
1 Install the needle roller bearing.
2 Install the gear wheel.
3 Install the synchronizer ring.





4. Assemble the third and fourth gear synchronizer.
1 Install the compression springs.
2 Install the synchronizer bar and detent balls by pressing against the spring pressure.
3 Install the selector ring the right way round and slide it on.





5. NOTE: Install the synchronizer hub with the large collar facing outwards and the annular groove facing the small collar.

Installation position of the synchronizer assembly shown.





6. NOTE: Install the synchronizer hub with the large collar facing outwards.

NOTE: Install a new snap ring.

NOTE: The snap ring thickness is 2.5 mm.

Install the complete third and fourth gear synchronizer assembly.
1 Install the synchronizer assembly.
2 Install the snap ring.





7. Install the fourth gear wheel.
1 Install the synchronizer ring.
2 Install the needle roller bearing.
3 Install the gear wheel.





8. NOTE: Install a new snap ring.

Press on the fifth gear wheel.
^ Using a length of suitable tube, press on the fifth gear wheel.
^ Install the snap ring.





9. Using a length of suitable tube, install the transaxle housing roller bearing.