Mainshaft Disassembly/Inspection/Reassembly

Disassembly





1. Support ball bearing (A) with a commercially available bearing separator, and remove the ball bearing using a press as shown.
2. Remove the 3rd gear, 35 x 30 x 35 mm needle bearing, distance collar, double cone synchro, synchro spring, and 3-4 synchro sleeve.





3. Support 4th gear (A) with a commercially available bearing separator, and remove the 3-4 synchro hub (B), double cone synchro, and 4th gear using a press as shown.
4. Remove the 42 x 47 x 30.5 mm needle bearing, distance collar, 5th gear, synchro ring, and synchro spring.





5. Support 6th gear (A) with a commercially available bearing separator, and remove the 5-6 synchro hub/sleeve (B), synchro ring, synchro spring, and 6th gear using a press as shown.
6. Remove the 39 x 44 x 26 mm needle bearing.





7. Support ball bearing (A) with a commercially available bearing separator, and remove the ball bearing using a press as shown.

Inspection
1. Inspect the gear surface and the bearing surface for wear and damage.





2. Measure the mainshaft at points A, B, C, and D. If any part of the mainshaft is less than the service limit, replace it with a new one.
Standard:
A (Rear cover end ball bearing contact area): 27.987 - 28.000 mm (1.1018 - 1.1024 inch)
B (4th/5th gears contact area): 34.987 - 35.000 mm (1.3774 - 1.3780 inch)
C (6th gear contact area): 38.984 - 39.000 mm (1.5348 - 1.5354 inch)
D (Clutch housing end ball bearing contact area): 28.002 - 28.015 mm (1.1024 - 1.1030 inch)
Service Limit:
A: 27.94 mm (1.100 inch)
B: 34.94 mm (1.376 inch)
C: 38.94 mm (1.533 inch)
D: 27.95 mm (1.100 inch)





3. Inspect for runout by supporting both ends of mainshaft. Rotate the mainshaft two complete revolutions when treasuring the runout. If the runout is more than the service limit, replace the mainshaft with a new one.
Standard: 0.02 mm (0.001 inch) maximum
Service Limit: 0.05 mm (0.002 inch)

Reassembly

Special Tools Required
^ Driver, 40 mm I.D. 07746-0030100
^ Attachment, 30 mm I.D. 07746-0030300

NOTE: Refer to the Exploded View as needed during this procedure.





1. Support 2nd gear (A) on steel blocks, then install the ball bearing (B) using the special tools and a press as shown.

NOTE: The thin edge of the outer race faces 6th gear.

2. Install the 39 x 44 x 26 mm needle bearing, 6th gear, synchro ring, and synchro spring.





3. Install the 5-6 synchro hub (A) and sleeve (B) by aligning the stops (C).





4. Press the 5-6 synchro hub using the special tool as shown. After installing, check the operation of the 5-6 synchro hub and sleeve.
5. Install the synchro spring, synchro ring, 42 x 47 x 30.5 mm needle bearing, 5th gear, distance collar, and 4th gear.





6. Install the double cone synchro (A) and synchro spring (B) as shown.





7. Install the 3-4 synchro hub (A) and sleeve (3) by aligning the stops (C).





8. Press the 3-4 synchro hub using the special tool as shown. After installing, check the operation of the 3-4 synchro hub and sleeve.





9. Install the double cone synchro (A) and synchro spring (B) as shown.





10. Install the distance collar (A), 35 x 40 x 35 mm needle bearing (B), and 3rd gear (C).





11. Install the angular ball bearing (A) with the thin edge of the outer race facing 3rd gear (B). Use the special tool and a press.