2. Remove the 4/5 speed synchronizer, 4th gear synchronizer ring and 4th gear. If the parts are tight on the shaft, use a puller, securing it to the back of the 4th gear pinion, or vice versa, secure the pinion pinion and pull the shaft out.
3. Remove the 4th gear needle bearing from the shaft.
Figure 6.41. Dual gear/reverse synchronizer ring.
4. From the rear end of the main shaft, remove the 2nd gear thrust washer, the 2nd gear pinion and its synchronizer ring.
5. Remove the 2nd gear roller bearing.
6. Remove the inner race of the needle bearing. If it is tight on the shaft, use a puller to remove the 2/3 speed synchronizer and 3rd gear pinion. Attach the puller to the rear surface of the 3rd gear.
Figure 6.42. 2/3 speed synchronizer ring. Pay attention to the groove (indicated by the arrow).
7. Remove the 3rd gear needle bearing.
8. After disassembling the main shaft, check for broken or damaged teeth on the gears, weak or rattling bearings, and faulty synchronizers.
9. Refer to Section 6 for information on general synchroniser rebuild, but note that on a five-speed gearbox the synchroniser ring identification is different to that described.
Figure 6.43. Detailed view of the main shaft without 1st/reverse gears: 1 - Spring clamp; 2 - 4/5 speed synchronizer; 3 - Synchronizer ring; 4 - 4th gear pinion; 5 - Needle bearing; 6 - Main shaft; 7 - Needle bearing; 8 - 3rd gear pinion; 9 - Synchronizer ring; 10 - 2/3 speed synchronizer; 11 - Inner race of needle bearing; 12 - Needle bearing; 13 - Synchronizer ring; 14 - 2nd gear pinion; 15 - Thrust washer; 16 - Synchronizer hub; 17 - Synchronizer sleeve; 18 - Spring; 19 - Sliding keys; 20 - Synchronizer hub; 21 - Synchronizer sleeve; 22 - Spring.
10. Begin assembly by lubricating and installing the 4th gear needle bearing onto the front end of the main shaft.
11. Install the 4th gear pinion, its synchronizer ring and the 4/5th speed synchronizer, making sure that the wider shoulder of the hub is facing the 4th gear pinion. Use a press or puller as needed.
12. Lubricate the 3rd gear needle bearing and install it onto the rear end of the main shaft.
13. Install the third gear pinion, its synchronizer ring and the 2/3 speed synchronizer. Note that the groove on the synchronizer sleeve is directed towards the 2nd gear gear. Use a puller to install these components in place, or insert the shaft into the synchronizer hub, securing its outer surface properly.
14. Install the inner race of the 2nd gear needle bearing.
15. Install the 2nd gear needle bearing well lubricated.
16. Install the 2nd gear synchronizer ring.
17. Install the 2nd gear gear and thrust washer.
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