FE03-0116b

7.

Pull  out  the  4th  gear  and  the  5th  gear  with  a  universal
bearing puller.

FE03-0117b

8.

Remove the 3rd gear and the 4th gear sleeve.

FE03-0118b

9.

Pull out the 3rd gear with a universal bearing puller.

Note

The gap between the 2nd gear and the 3rd gear is
very small. Pulling out after a certain distance, then
pull the 3rd gear separately.

Transmission / Drive Axle

Manual Transmission

3-95

FE03-0119b

10. Remove the 2nd gear bearing.

Note

This  needle  bearing  has  no  opening  and  can  be
directly removed.

FE03-0120b

11. Remove the 1st and 2nd gear synchronizer snap ring with

a plier.

FE03-0121b

12. Remove the 1st and 2nd gear synchronizer.

Gear Synchronizer Sleeve and Shift Fork Distance:
≤0.35 mm (13.780 × 10

-3

 in)

3-96

Manual Transmission

Transmission / Drive Axle

FE03-0122b

13. Remove the 1st gear.

FE03-0123b

14. Remove the 1st gear needle bearing.

Note

The bearing has only one opening. Do not force to
remove, as it may damage the bearing.

FE03-0124b

15. After disassemble, the main shaft final state is:

Main shaft Wear:
Minimum Diameter 33.985 mm (1,337.989 × 10

-3

 in)

Main shaft Runout:
≤0.03 mm (1.181 × 10

-3

 in)

Transmission / Drive Axle

Manual Transmission

3-97

Installation Procedure:

GL201-005

FE03-0125b

1.

Install the 1st gear needle bearing.

Note

Apply  a  small  amount  of  transmission  fluid  to  the
bearing journal before installation.
If  the  bearings  need  to  be  replaced,  the  bearing
outer  ring  also  need  to  be  replaced.  During  the
removal, please use a special tool GL201-005.

FE03-0126b

2.

Install the 1st gear.

FE03-0127b

3.

Install the 1st and 2nd gear synchronizer.

Note

Gear side should face the rear of the transmission.

3-98

Manual Transmission

Transmission / Drive Axle