2. Clamp the shaft in a vise using two dies to protect it from damage. Measure the gear clearances with a feeler gauge and compare the results with the data given in Specifications (photo).
Measure the gear gaps with a feeler gauge
3. Use a puller to remove the shaft end roller bearing. Remove the 4th gear.
4. Remove the synchronizer blocking ring.
5. Remove the 3rd and 4th gear synchronizer circlips.
6. Gently pull the 3rd and 4th gear synchronizer off the shaft.
7. Remove the 3rd gear lock ring.
8. Remove the 3rd gear assembly.
9. Remove the thrust washer circlip and washers.
10. Remove the 2nd gear.
11. Remove the synchronizer blocking ring.
12. Remove the 1st gear retaining ring.
13. Special tools are required to remove the 1st gear and the 1st and 2nd gear synchronizer assembly. This procedure must be entrusted to the dealer.
14. Remove the bearing using a puller.
15. Inspect the gear and synchronizer for wear and damage.
16. Check the output shaft for wear or damage to friction and contact surfaces, grooves or teeth. Also, check if the oil passages are clogged.
17. Reinstall the synchronizer rings to make sure they slide smoothly and smoothly. Measure the gap with a feeler gauge and compare the value obtained with the data given in Specifications (photo).
Make sure the synchronizer ring moves freely
18. Inspect the synchronizer and fork for damage and wear.
19. Disassemble the synchronizer and inspect its grooves and working surfaces for wear. Inspect the springs to make sure they are not deformed or weakened.
20. Assemble the synchronizer. The raised part of the crackers should be facing the outer edge of the hub. When installing the spring, make sure that it falls into the corresponding recesses of the crackers.
21. Measure the gap between the synchronizer and the fork with a feeler gauge (photo).
Measure the gap between the synchronizer and the fork
22. Replace any worn or damaged components with new ones.
23. Install the bearing on the end of the shaft.
24. Turn the shaft over and install the 1st and 2nd gear synchronizer with the fork groove down.
25. Establish persistent rings of assembly of gear wheels of 1st and 2nd transfers.
26. Install the blocking ring on the synchronizer, aligning its groove with the hub crackers.
27. Install the 2nd gear.
28. Install the synchronizer blocking ring on the hub, aligning its groove with the hub crackers.
29. Install the thrust washer circlips.
30. Install the 3rd gear and 3rd gear synchronizer ring.
31. Install the 3rd/4th gear synchronizer with the grooved side down. A press may be required for installation.
32. Install the 3rd/4th gear snap ring.
33. Install the 4th gear synchronizer ring, and then the gear itself.
34. To remove the bearing from the shaft, contact your dealer or workshop.