Mainshaft: Service and Repair

TOOLS REQUIRED
- 07746-0030100 Driver, 40 mm I.D.
- 07746-0030400 Attachment, 35 mm I.D.
- 07749-0010000 Driver
- 07746-0010300 Attachment, 42 x 47 mm
- Or Equivalent





1. Remove the mainshaft and countershaft assemblies with the shift forks from the clutch housing.

NOTE: Before removing the mainshaft and countershaft assemblies, tape the mainshaft splines to protect them.

3. Inspect mainshaft assembly clearance, wear and damage.

NOTE: Measure the Mainshaft gear clearances prior to disassembly. Testing and Inspection

DISASSEMBLE





4. Remove the ball bearing and the stop ring using a bearing separator and a bearing puller. Be sure the bearing separator is under the stop ring.

CAUTION: Remove the synchro hubs using a press and steel blocks as shown. Use of a jaw-type puller can cause damage to the gear teeth.





5. Support 5th gear on steel blocks, and press the mainshaft out of the 5th synchro hub.





6. In the same manner as above, support the 3rd gear on steel blocks, and press the mainshaft out of the 3rd/4th synchro hub.





ASSEMBLE

NOTE:
- Inspect mainshaft assembly for clearance, wear and damage.
- Measure the Mainshaft gear clearances prior to disassembly. Testing and Inspection

- The 3rd/4th, and 5th synchro hubs, and the ball bearing are installed with a press. Prior to reassembling, clean all the parts in solvent, dry them, and apply lubricant to any contact surfaces. The 3rd/4th and 5th synchro hubs, however, should be installed with a press before lubricating them.





1. Support 2nd gear on steel blocks as shown, then install the 3rd/4th synchro hub dry (no lubricant) using the special tools and a press.

NOTE: After installing, inspect the operation of the 3rd/4th synchro hub set.





2. Install the 5th synchro hub dry (no lubricant) using the special tools and a press.





3. Install the ball bearing using the special tools and a press.