Output shaft — disassembly and assembly

Special tool

	Bearing puller (main instrument) 205-295 (15-050A)
	308-045 Bushing/Oil Seal Installer (16-015)
	Collet for 205-295 307-217 (17-048)

General equipment:

• Double bearing puller
• Press
• Retaining ring

Name	Specification
Transmission Fluid for Manual Transmission	WSD-M2C200-C

Disassembly

1. Remove the roller bearing and fourth gear.

• 1. Remove the small circlip and discard it as no longer needed.
• 2. Install the appropriate circlip.
• 3. Using an appropriate double bearing puller, remove the roller bearing.
• 4. Remove the fourth gear and synchronizer ring.

2. Remove the third and fourth gear synchronizer assembly.

• 1. Remove the circlip and discard it as no longer needed.
• 2. Remove the synchronizer, third and fourth gear synchronizer assembly and third gear.

3. Remove the third gear synchronizer ring from the third gear.

• 1. Synchronizer outer ring
• 2. Tapered synchronizer ring
• 3. Third gear.

4.

NOTE: Dual synchronizer shown, service replacement item.

Disassemble the third gear synchronizer assembly.

• 1. Synchronizer outer ring
• 2. Tapered synchronizer ring
• 3. Synchronizer inner ring
• 4. Third gear.

5. Remove the second gear and synchronizer assembly.

• 1. Retaining ring
• 2. Retaining rings
• 3. Second gear
• 4. Synchronizer inner ring
• 5. Tapered synchronizer ring
• 6. Synchronizer outer ring

6.

NOTE: Remove the synchronizer assembly with the first gear.

Remove the first gear and reverse gear, synchronizer and synchronizer assembly.

• 1. Remove the circlip and discard it as no longer needed.
• 2. Remove the first and second gear synchronizer and reverse gear.
• 3. Synchronizer outer ring
• 4. Tapered synchronizer ring
• 5. Synchronizer inner ring
• 6. First gear.

7.

CAUTION: To facilitate assembly, mark the position of the synchronizer sleeve relative to the synchronizer hub.

Disassemble the synchronizer hub.

• 1. Synchronizer clutch
• 2. Synchronizer spring
• 3. Cracker synchronizer
• 4. Synchronizer hub

8.

NOTE: Install stop in oil funnel opening.

Using the special tools, remove the inner output shaft bearing.

• 1. Remove the circlip and discard it as no longer needed.
• 2. Install the special tools below the bearing inner race.

Assembly

CAUTION: Before reassembly, immerse the dual synchronizer assembly in clean manual transmission fluid.

1. Thoroughly clean and inspect all running surfaces and coat with clean manual transmission fluid prior to assembly.

2.

NOTE: Install a new mainshaft bearing inner race circlip.

Install the secondary shaft bearing inner race.

• Heat the bearing inner race evenly to approximately 80°C and install it on the output shaft.
• Install retaining ring.

3.

NOTE: Assemble the synchronizer hub according to the marks.

Assemble the synchronizer hub.

• 1. Synchronizer hub
• 2. Install the synchronizer sleeve onto the synchronizer hub.
• 3. Install the synchronizer cotters.
• 4. Install the synchronizer spring.

4.

NOTE: Use a new 1st and reverse gear circlip.

Install the first gear and reverse gear, synchronizer and synchronizer assembly.

• 1. First gear.
• 2. Synchronizer inner ring
• 3. Tapered synchronizer ring
• 4. Synchronizer outer ring
• 5. Install the first and second gear synchronizer and reverse gear.
• 6. Install retaining ring.

5.

NOTE: Before installing on the output shaft, assemble the synchronizer assembly.

Install the second gear with synchronizer assembly.

• 1. Synchronizer outer ring
• 2. Tapered synchronizer ring
• 3. Synchronizer inner ring
• 4. Second gear
• 5. Retaining rings
• 6. Retaining ring

6.

NOTE: Dual synchronizer shown, service replacement item.

Assemble the third gear synchronizer assembly.

• 1. Third gear.
• 2. Synchronizer inner ring
• 3. Tapered synchronizer ring
• 4. Synchronizer outer ring

7. Install the 3rd gear synchronizer ring onto the 3rd gear.

• 1. Third gear.
• 2. Tapered synchronizer ring
• 3. Synchronizer outer ring

8.

NOTE: Install a new 3rd and 4th gear synchronizer spring assembly.

NOTE: Install the synchronizer sleeve with the annular groove facing down and the small protrusion of the hub facing up.

Install the 3rd and 4th gear synchronizer assembly.

• 1. Install the synchronizer, 3rd/4th gear synchronizer assembly and 3rd gear.
• 2. Install retaining ring.

9.

NOTE: Install a new roller bearing circlip.

NOTE: Install the roller bearing with the annular groove facing out.

Using the special tool and appropriate press, install the 4th gear and roller bearing.

• 1. Install the synchronizer ring and fourth gear.
• 2. Using an appropriate press, install the roller bearing.
• Install retaining ring.