Mainshaft Disassembly, Reassembly, and Inspection
Special Tools Required
Image Description/Tool Number
310166.png Driver Handle, 40 mm I.D. 07746-0030100
1498015.png Bearing Driver Attachment, 25 mm I.D. 07746-0030200
310167.png Bearing Driver Attachment, 30 mm I.D. 07746-0030300
310219.png Bearing Separator 07KAF-PS30200
1. Mainshaft - Exploded View

Exploded View



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

1. Mainshaft - Disassemble
1.
Support 6th gear (A) on the bearing separator, and press the mainshaft out of the angular ball bearing (B) and 6th gear.
2.
Support 5th gear (A) on the bearing separator, and press the mainshaft out of the 5th/6th synchro hub, synchro spring, the synchro ring, and 5th gear.
3.
Support 3rd gear (A) on the bearing separator, and press the mainshaft out of the 3rd/4th synchro hub, the synchro spring, the synchro ring, 3rd gear, and the needle bearing.

1. Mainshaft - Inspect
1.
Inspect the oil passage, gear, and bearing contact areas for wear and damage, then measure the mainshaft at points A, B, C, D, and E. If any part of the mainshaft is less than the service limit, replace it.
Standard:
A
Ball Bearing Contact Area
 
(Transmission Housing Side):
 
24.987?25.000 mm (0.98374?0.98425 in)
B
4th/5th Gear Distance Collar Contact Area:
 
28.992?29.005 mm (1.14142?1.14193 in)
C
Needle Bearing Contact Area:
 
34.984?35.000 mm (1.37732?1.37795 in)
D
Ball Bearing Contact Area
 
(Clutch Housing Side):
 
25.977?25.990 mm (1.02271?1.02323 in)
E
Pilot Bearing Contact Area:
 
14.87?14.89 mm (0.5854?0.5862 in)
Service Limit:
A:
24.987 mm (0.98374 in)
B:
28.992 mm (1.14142 in)
C:
34.984 mm (1.37732 in)
D:
25.977 mm (1.02271 in)
E:
14.87 mm (0.5854 in)
2.
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: Refer to the Exploded View as needed during this procedure.

1. Mainshaft - Reassemble
1.
Clean all parts in solvent, dry them, and apply MTF to all contact surfaces.
2.
Install the needle bearing (A) and 3rd gear (B) onto the mainshaft (C).
3.
Install the synchro ring (A) with the synchro spring (B) onto 3rd gear (C).
4.
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.
5.
Press on the 3rd/4th synchro hub (A) using the 40 mm I.D. driver handle.
6.
Install the 3rd/4th synchro sleeve (A) by aligning the stops (B) of the 3rd/4th synchro sleeve and the 3rd/4th synchro hub. After installation, check the operation of the 3rd/4th synchro hub set.
7.
Install the synchro ring (A) with the synchro spring (B) by aligning the synchro ring fingers (C) with the grooves (D) in the 3rd/4th synchro hub.
8.
Install 4th gear (A) onto the synchro ring (B).
9.
Install the 4th/5th gear distance collar (A) with the needle bearings (B) and 5th gear (C).
10.
Install the synchro ring (D) with the synchro spring (E) onto 5th gear.
11.
Install the 5th/6th synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 5th/6th synchro hub.
12.
Press on the 5th/6th synchro hub (A) using the 40 mm I.D. driver handle and the 30 mm I.D. bearing driver attachment.
13.
Install the 5th/6th synchro sleeve (A) by aligning the slots of the 5th/6th synchro sleeve and the 5th/6th synchro hub (B). After installation, check the operation of the 5th/6th synchro hub set.
NOTE: Make sure to align the slots in the 5th/6th synchro hub as shown.
14.
Install the synchro ring (A) with the synchro spring (B) by aligning the synchro ring fingers (C) with the grooves (D) in the 5th/6th synchro hub.
15.
Install the 6th gear distance collar (E) with the needle bearing (F) and 6th gear (G).
16.
Press on a new angular ball bearing (A) using the 40 mm I.D. driver handle, the 25 mm I.D. bearing driver attachment, and a press (B).
NOTE: Make sure the angular ball bearing is installed in the correct direction.