Main Shaft Assembly
A: DISASSEMBLY2500 cc Model
1. Assemble sleeve and hub assembly for 3rd-4th and, 5th synchronizing.
NOTE: Position open ends of spring 120° apart.
2. Install 3rd drive gear, outer baulk ring, synchro cone, inner baulk ring, sleeve and hub assembly for 3rd needle bearing on transmission main shaft.
NOTE: Align groove in baulk ring with insert key.
3. Install 4th needle bearing race onto transmission main shaft using Service Tool (ST)1, (ST)2 and a press.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
4. Install baulk ring, needle bearing (32 x 30 x 25.7), 4th drive gear and 4th gear thrust washer to transmission main shaft.
5. Drive ball bearing onto the rear section of transmission main shaft using ST1, ST2 and a press.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
6. Using ST1 and ST2, install the 5th gear thrust washer and 5th needle bearing race onto the rear section of transmission main shaft.
NOTE: Face thrust washer in the correct direction.
ST1 899714110 REMOVER
ST2 499877000 RACE 4-5 INSTALLER
7. Install bearing onto synchro cone.
8. Install baulk ring and synchro cone onto 5th-Rev sleeve and hub assembly using ST and a press.
NOTE:
- Use new ball bearing.
- After press fitting, make sure synchro cone rotates freely.
ST 499757002 SNAP RING PRESS
9. Install synchro cone stopper and snap ring to 5th-Rev sleeve and hub assembly.
10. Install the rest parts to the rear section of transmission main shaft.
NOTE: Align groove in baulk ring with shifting insert.
ST1 499987003 SOCKET WRENCH
ST2 498937000 TRANSMISSION HOLDER
11. Tighten lock nuts to the specified torque using ST1 and ST2.
NOTE: Secure lock nuts in two places after tightening.
ST1 499987000 SOCKET WRENCH
ST2 498937000 TRANSMISSION HOLDER
Tightening torque: 18 ± 6 Nm (12.0 ± 0.6 kg-m, 86.8 ± 4.3 ft. lbs.)