Mainshaft Disassembly, Reassembly, and Inspection (K20C1 (M/T))

Mainshaft Disassembly, Reassembly, and Inspection

Special Tools Required

Image	Description/Tool Number
	Driver Handle, 40 mm I.D. 07746-0030100
	Driver, 30 mm I.D. 07946-MB00000

NOTE:

Where icon is shown, click for further information.

	Detailed information, notes, and precautions
	Replace
*1	Double cone synchro assembly

1.	Angular Ball Bearing - Remove

Support 6th gear (A) on steel blocks, and press the mainshaft out of the angular ball bearing (B) using an attachment (C) and a press (D).

NOTE: Do not use a jaw-type puller; it can damage the gear teeth.

2.	6th Gear - Remove

3.	Needle Bearing - Remove

4.	6th Gear Distance Collar - Remove

5.	Synchro Ring - Remove

6.	Synchro Spring - Remove

7.	5th/6th Synchro Sleeve - Remove

8.	5th/6th Synchro Hub - Remove

Support 5th gear (A) on steel blocks, and press the mainshaft out of the 5th/6th synchro hub (B) using an attachment (C) and a press (D).

NOTE: Do not use a jaw-type puller; it can damage the gear teeth.

9.	Synchro Spring - Remove

10.	Synchro Ring - Remove

11.	5th Gear - Remove

12.	Needle Bearing - Remove

13.	4th/5th Gear Distance Collar - Remove

14.	Needle Bearing - Remove

15.	4th Gear - Remove

16.	Inner Ring - Remove

17.	Synchro Cone - Remove

18.	Synchro Ring - Remove

19.	Synchro Spring - Remove

20.	3rd/4th Synchro Sleeve - Remove

21.	3rd/4th Synchro Hub - Remove

Support 3rd gear (A) on steel blocks, and press the mainshaft out of the 3rd/4th synchro hub (B) and 3rd gear using an attachment (C) and a press (D).

NOTE: Do not use a jaw-type puller; it can damage the gear teeth.

22.	Synchro Spring - Remove

23.	Synchro Ring - Remove

24.	Synchro Cone - Remove

25.	Inner Ring - Remove

26.	3rd Gear - Remove

27.	Needle Bearing - Remove

28.	Angular Ball Bearing - Remove

Support the angular ball bearing (A) on steel blocks, and press out the mainshaft using an attachment (B) and a press (C).

1.	Mainshaft - Inspect

Inspect the oil passage, gear, and bearing contact areas for wear and damage, then measure the mainshaft at points A, B, C, D, E, and F. If any part of the mainshaft is less than the service limit, replace it.

	Measurement	Standard	Service Limit
A	Ball Bearing Contact Area (Transmission Housing Side)	38.984?39.000 mm (1.53480?1.53543 in)	38.984 mm (1.53480 in)
B	6th Gear Distance Collar Contact Area	38.984?39.000 mm (1.53480?1.53543 in)	38.984 mm (1.53480 in)
C	4th/5th Gear Distance Collar Contact Area	41.984?42.000 mm (1.65291?1.65354 in)	41.984 mm (1.65291 in)
D	Needle Bearing Contact Area	47.984?48.000 mm (1.88913?1.88976 in)	47.984 mm (1.88913 in)
E	Ball Bearing Contact Area (Clutch Housing Side)	28.002?28.015 mm (1.10244?1.10295 in)	28.002 mm (1.10244 in)
F	Flywheel Pilot Bearing Contact Area	19.967?19.980 mm (0.78610?0.78661 in)	19.967 mm (0.78610 in)

Inspect the runout by supporting both ends of the mainshaft. Then rotate the mainshaft two complete turns while measuring with a dial gauge. If the runout exceeds the standard, replace the mainshaft.

Standard:

0.02 mm (0.0008 in) max.

NOTE:

Where icon is shown, click for further information.

Clean all parts in solvent, dry them, and apply MTF to all contact surfaces.

	Detailed information, notes, and precautions
	Replace
*1	Double cone synchro assembly

1.	Angular Ball Bearing - Install

Press in a angular ball bearing (A) using the 30 mm I.D. driver and a press (B).

NOTE: Check the ball bearing install direction.

2.	Needle Bearing - Install

3.	3rd Gear - Install

4.	Inner Ring - Install

5.	Synchro Cone - Install

Install the synchro cone (A) by aligning the synchro cone fingers (B) with the holes (C) in the 3rd gear.

6.	Synchro Ring - Install

Install the synchro ring (A) by aligning the synchro ring fingers (B) with the grooves (C).

7.	Synchro Spring - Install

8.	3rd/4th Synchro Hub - Install

Install the 3rd/4th synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 3rd/4th synchro hub.

NOTE: Make sure to install the 3rd/4th synchro hub in the direction shown.

Press on the 3rd/4th synchro hub (A) using the 40 mm I.D. driver handle and a press (B).

9.	3rd/4th Synchro Sleeve - Install

Install the 3rd/4th synchro sleeve (A) by aligning the stops (B) of the 3rd/4th synchro sleeve and the 3rd/4th synchro hub.

Check the operation of the 3rd/4th synchro hub set.

10.	Synchro Spring - Install

11.	Synchro Ring - Install

Install the synchro ring (A) by aligning the synchro ring fingers (B) with the grooves (C) in 3rd/4th synchro hub.

12.	Synchro Cone - Install

13.	Inner Ring - Install

Install the inner ring (A) by aligning the synchro ring fingers (B) with the grooves (C) in the inner ring.

14.	4th Gear - Install

Install 4th gear (A) by aligning the synchro cone fingers (B) with the holes (C) in 4th gear.

15.	Needle Bearing - Install

16.	4th/5th Gear Distance Collar - Install

17.	Needle Bearing - Install

18.	5th Gear - Install

19.	Synchro Ring - Install

20.	Synchro Spring - Install

21.	5th/6th Synchro Hub - Install

Install the 5th/6th synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 5th/6th synchro hub.

NOTE: Make sure to install the 5th/6th synchro hub in the direction shown.

Press on the 5th/6th synchro hub (A) using the 40 mm I.D. driver handle and a press (B).

22.	5th/6th Synchro Sleeve - Install

Install the 5th/6th synchro sleeve (A) by aligning the slots of the 5th/6th synchro sleeve and the 5th/6th synchro hub (B).

NOTE: Make sure to align the slots in the 5th/6th synchro sleeve as shown.

Check the operation of the 5th/6th synchro hub set.

23.	Synchro Spring - Install

24.	Synchro Ring - Install

Install the synchro ring (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 5th/6th synchro hub.

25.	6th Gear Distance Collar - Install

26.	Needle Bearing - Install

27.	6th Gear - Install

28.	Angular Ball Bearing - Install

Press on an angular ball bearing (A) using the 40 mm I.D. driver handle and a press (B).

NOTE: Make sure the angular ball bearing is installed in the correct direction.