Secondary shaft (cars after 08.2000) — disassembly and assembly

Special tool

	Pinion Bearing Installation Tool 205-068 (15-042)
	Bearing Puller (Main Tool) 205-295 (15-050A)
	Bearing/Gear Puller 205-310 (15-091)
	Collet for 205-095 308-197 (16-062)

Name	Specification
Transmission fluid for manual transmission	WSD-M2C200-C

Disassembly

1. Using the special tool, remove the roller bearing of the gearbox housing in the block with the drive axle.



2. Remove the reverse gear gear.

• 1. Remove the reverse gear gear.
• 2. Remove the needle roller bearing.
• 3. Remove the synchronizer ring.

3.

NOTE: If gear shifting is difficult, carefully remove the synchronizer hub and fifth gear.

Remove the fifth gear pinion and the reverse gear synchronizer hub.

• 1. Remove the retaining ring.
• 2. Remove the synchronizer hub assembly.

4. Remove the fifth gear.

• 1. Remove the synchronizer ring.
• 2. Remove the fifth gear.
• 3. Remove the needle roller bearing.

5.

Note: Use a special tool so that the flat side is facing up.

Using a special tool, remove the fourth gear.

• Remove the retaining ring.

6.

Note: Use a special tool so that the flat side is facing up.

Using a special tool, remove the second and third gear pinion.



7.

CAUTION: Use extreme caution when handling the inner synchronizer ring and the tapered synchronizer ring.

Remove the second gear gear.

• 1. Remove the needle roller bearing.
• 2. Remove the second gear.
• 3. Remove the inner synchronizer ring.
• 4. Remove the conical synchronizer ring.
• 5. Remove the outer synchronizer ring.

8. Remove the first and second gear synchronizer hub assembly.

• 1. Remove the retaining ring.
• 2. Remove the synchronizer hub assembly.

9.

CAUTION: Use extreme caution when handling the inner synchronizer ring and the tapered synchronizer ring.

Remove the first gear gear.

• 1. Remove the outer synchronizer ring.
• 2. Remove the inner synchronizer ring.
• 3. Remove the conical synchronizer ring.
• 4. Remove the first gear.
• 5. Remove the needle roller bearing.

10.

NOTE: Should only be removed if a new bearing is to be installed.

Using a special tool, remove the clutch housing roller bearing.



11.

CAUTION: Use caution when removing the synchronizer sleeve from the synchronizer hub. The detent balls are spring loaded.

NOTE: Mark the installation position of the synchronizer sleeve.

Disassemble the synchronizer hub assembly.

• 1. Remove the synchronizer sleeve.
• 2. Remove the synchronizer hub.
• 3. Remove the compression springs.
• 4. Remove the breadcrumbs.
• 5. Remove the locking balls.

Assembly

1.

CAUTION: Be extremely careful when handling the inner synchronizer ring and the tapered synchronizer ring. Soak the synchronizer rings in transmission fluid before installation.

NOTE: Do not lubricate roller bearings.

Before assembly, clean and thoroughly inspect all parts and lubricate all moving parts with transmission fluid.

2.

CAUTION: Use extreme caution when handling the inner synchronizer ring and the tapered synchronizer ring.

Install the first gear gear.

• 1. Install the needle roller bearing.
• 2. Install the first gear pinion.
• 3. Install the inner synchronizer ring.
• 4. Install the conical synchronizer ring.
• 5. Install the outer synchronizer ring.

3.

NOTE: Pay attention to the markings.

Assemble the synchronizer hub.

• 1. Install the compression springs.
• 2. Install the crackers and locking balls into the synchronizer hub, overcoming the spring force.
• 3. Install the spring ring and secure it.

4.

NOTE: Install the synchronizer hub so that the large projection faces outward (towards the second gear).

Install the first and second gear synchronizer hub assembly.

• 1. Install the synchronizer hub assembly.
• 2. Install the retaining ring.

5. Install the second gear gear.

• 1. Install the needle roller bearing.
• 2. Install the outer synchronizer ring.
• 3. Install the conical synchronizer ring.
• 4. Install the inner synchronizer ring.
• 5. Install the second gear gear.

6. Using the special tool, install the third gear gear.



7.

NOTE: Install a new snap ring.

Using the special tool, install the fourth gear pinion.



8. Install the fifth gear.

• 1. Install the needle roller bearing.
• 2. Install the fifth gear.
• 3. Install the synchronizer ring.

9.

NOTE: Install the synchronizer hub so that the small projection and the annular groove face outward.

Installation position of the reverse and fifth gear synchronizer hub.



10.

NOTE: Install the synchronizer hub so that the small projection and the annular groove face outward.

Install the 5th and reverse gear synchronizer assembly.

• 1. Install the synchronizer hub.
• 2. Install a new snap ring.

11. Install the reverse gear gear.

• 1. Install the synchronizer ring.
• 2. Install the needle roller bearing.
• 3. Install the reverse gear gear.

12. Using a suitable piece of pipe, install the transmission housing roller bearing into the transaxle assembly.



13. Using a suitable piece of pipe, install the new clutch housing roller bearing.