M/T Mainshaft Reassembly

Exploded View 5-speed model: 6-speed model: 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.
- 6-speed model is shown, 5-speed model similar.

1. Clean all the parts in solvent, dry them, and apply lubricant to all contact surfaces except the 3rd/4th and 5th/6th synchro hubs.

1. Install the needle bearing and 3rd gear on the mainshaft.

1. Install the double cone synchro assembly (A) by aligning the synchro cone fingers (B) with the holes in 3rd gear (C), then install the synchro spring (D).

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

1. Install the 3rd/4th synchro hub (A) using the special tool.

1. Install the 3rd/4th synchro sleeve (A) by aligning the stops (B) with the 3rd/4th synchro sleeve and hub. After installing, check the operation of the 3rd/4th synchro hub set.

1. Install the synchro spring (A).

1. Install the double cone synchro assembly (B) by aligning the synchro cone fingers (C) with the grooves in 3rd/4th synchro hub (D).

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

1. Install the needle bearings, distance collar, and 5th gear.

1. Install the double cone synchro assembly (A) by aligning the synchro cone fingers (B) with the holes in 5th gear (C), then install the synchro spring (D).

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

1. Install the 5th/6th synchro hub (A) using the special tools.

1. Install the 5th/6th synchro sleeve.

1. Install the distance collar and the tapered cone ring (5-speed model).

1. Install the synchro spring (A).

1. Install the double cone synchro assembly (B) by aligning the synchro cone fingers (C) with the grooves in 5th/6th synchro hub (D).

1. Install the distance collar and the needle bearing.

1. Install the 6th gear (A) by aligning the synchro cone fingers (B) with the holes in 6th gear (C).

1. Install the new ball bearing (A) using the special tools and a press (B).