Mainshaft Disassembly, Reassembly, and Inspection
Special Tools Required
Image Description/Tool Number
310166.png Driver Handle, 40 mm I.D. 07746-0030100
609759.png Driver, 30 mm I.D. 07946-MB00000

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

1. Mainshaft - Disassemble
1.
Support 6th gear (A) on steel blocks, and press the mainshaft out of the angular ball bearing (B) and 6th gear using an attachment (C) and a press (D).
NOTE: Do not use a jaw-type puller; it can damage the gear teeth.
2.
Support 5th gear (A) on steel blocks, and press the mainshaft out of the 5th/6th synchro hub (B) and 5th gear using an attachment (C) and a press (D).
NOTE: Do not use a jaw-type puller; it can damage the gear teeth.
3.
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.
4.
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
1.
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.
Standard:
A Ball Bearing Contact Area (Transmission Housing Side):
 
30.987?31.000 mm (1.21996?1.22047 in)
B 6th Gear Distance Collar Contact Area:
 
32.987?33.000 mm (1.29870?1.29921 in)
C 4th/5th Gear Distance Collar Contact Area:
 
35.987?36.000 mm (1.41681?1.41732 in)
D Needle Bearing Contact Area:
 
41.984?42.000 mm (1.65291?1.65354 in)
E Ball Bearing Contact Area (Clutch Housing Side):
 
28.002?28.015 mm (1.10244?1.10295 in)
F Pilot Bearing Contact Area:
 
19.967?19.980 mm (0.78610?0.78661 in)
Service Limit:
A:
30.987 mm (1.21996 in)
B:
32.987 mm (1.29870 in)
C:
35.987 mm (1.41681 in)
D:
41.984 mm (1.65291 in)
E:
28.002 mm (1.10244 in)
F:
19.967 mm (0.78610 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.

1. Mainshaft - Exploded View

Exploded View



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.
Press in a new angular ball bearing (A) using the 30 mm I.D. driver and a press (B).
NOTE: Check the ball bearing install direction.
3.
Install the needle bearing (A).
4.
Install 3rd gear (B).
5.
Install the double cone synchro assembly (A) with the synchro spring (B) by aligning the synchro cone fingers (C) with the holes (D) in 3rd gear.
6.
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.
7.
Press on the 3rd/4th synchro hub (A) using the 40 mm I.D. driver handle and a press (B).
8.
Install the 3rd/4th synchro sleeve (A) by aligning the stops (B) of the 3rd/4th synchro sleeve and the 3rd/4th synchro hub.
9.
Check the operation of the 3rd/4th synchro hub set.
10.
Install the double cone synchro assembly (A) with the synchro spring (B) by aligning the synchro ring fingers (C) with the grooves (D) in the 3rd/4th synchro hub.
11.
Install 4th gear (A) by aligning the synchro cone fingers (B) with the holes (C) in 4th gear.
12.
Install the 4th/5th gear distance collar (A) with the needle bearings (B) and 5th gear (C).
13.
Install the synchro ring (D) with the synchro spring (E) onto 5th gear.
14.
Install the 5th/6th synchro hub (A) by aligning the synchro ring fingers (B) with the grooves (C) in the 5th/6th synchro hub.
15.
Press on the 5th/6th synchro hub (A) using the 40 mm I.D. driver handle and a press (B).
16.
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.
17.
Check the operation of the 5th/6th synchro hub set.
18.
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.
19.
Install the 6th gear distance collar (E) with the needle bearing (F) and 6th gear (G).
20.
Press on a new angular ball bearing (A) using the 40 mm I.D. driver handle and a press (B).
NOTE: Check the ball bearing install direction.