DISASSEMBLY AND REASSEMBLY



Disassembly steps
<<A>>
 >>F<<
 1.
 Fixed gear 6th
<<B>>
 >>E<<
 2.
 Fixed gear 5th


3.
 Speed gear 4th


4.
 Needle bearing


5.
 Dog body 4th
<<C>>
 >>D<<
 6.
 Needle bearing inner race
<<C>>
 >>C<<
 7.
 Synchronizer unit 2/4
<<C>>
8.
 Speed gear 2nd


9.
 Needle bearing


10.
 Clamp ring


11.
 Split shim


12.
 Speed gear 3rd


13.
 Dog body 3rd


14.
 Needle bearing
<<D>>
 >>B<<
 15.
 Snap ring
<<E>>
 >>A<<
 16.
 Synchronizer unit 1/3
<<E>>
17.
 Speed gear 1st


18.
 Needle bearing


19.
 Output shaft

DISASSEMBLY SERVICE POINT

<<A>> FIXED GEAR 6TH REMOVAL

Using the special tools, support the fixed gear 6th and remove the fixed gear 6th.

  • Gear remover (MB992257)
  • Valve guide installer (MD999588)

<<B>> FIXED GEAR 5TH REMOVAL

Using the special tools, Gear remover (MB992257) support the fixed gear 5th and remove the fixed gear 5th.

<<C>> NEEDLE BEARING INNER RACE / SYNCHRONIZER UNIT 2/4 / SPEED GEAR 2ND REMOVAL

Using the special tool, Bearing remover (MD998917) support the speed gear 2nd and remove the needle bearing inner race synchronizer unit 2/4, and speed gear 2nd.

<<D>> SNAP RING REMOVAL

Remove the snap ring of the output shaft.

<<E>> SYNCHRONIZER UNIT 1/3 / SPEED GEAR 1ST REMOVAL

Using the special tool, Bearing remover (MD998917) support the speed gear 1st and remove the synchronizer unit 1/3 and speed gear 1st.

REASSEMBLY SERVICE POINT

>>A<< SYNCHRONIZER UNIT 1/3 INSTALLATION

Using special tools, install the synchronizer unit 1/3.

  • Installer cap (MD998812)
  • Installer-200 (MD998814)
  • Installer adapter (MD998825)

>>B<< SNAP RING INSTALLATION

Install the snap ring that has selected.
note Try to first install the thicker snap ring to always use the thickest snap ring.

>>C<< SYNCHRONIZER UNIT 2/4 INSTALLATION

Using special tools, install the synchronizer unit 2/4.

  • Installer cap (MD998812)
  • Installer-200 (MD998814)
  • Installer adapter (MD998825)

>>D<< NEEDLE BEARING INNER RACE INSTALLATION

Using special tools, install the needle bearing inner race.

  • Installer cap (MD998812)
  • Installer-200 (MD998814)
  • Installer adapter (MD998819)

>>E<< FIXED GEAR 5TH INSTALLATION

Using special tools, install the fixed gear 5th.

  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer adapter (MD998819)

>>F<< FIXED GEAR 6TH INSTALLATION

Using special tools, install the fixed gear 6th.

  • Installer cap (MD998812)
  • Installer-100 (MD998813)
  • Installer adapter (MD998819)