Disassembly And Assembly: MAINSHAFT: Assembly

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1. Position the main shaft (1) in a vice as shown.

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2. Install the roller cage (1).

ASSEMBLY OF THE 1ST/2ND TRANSMISSION HUB COMPONENTS 

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The standard sizes of the synchronizer key are the following:

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1. Align the synchronizer rings grooves (1a) with the cones internal teeth (1b).
2. Assemble the synchronizer rings gears and components aligning the double cones teeth (2a) with the gear holes (2b) as illustrated in the figure.
3. Align the damper teeth (3a) with the grooves (3b) on the hub (3c) of the clutch.

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4. Align the clutch hub alignment marker (1a) with the installation position of the hub synchronizer key (1b).
5. Assemble the sleeve (2a) and hub (2b), securing the ends (2c) of the retaining clips (2d) for the keys to the seats.

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6. Assemble the synchronizer ring (1a), internal cone (1b), double cone (1c).

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7. On the hydraulic press using a suitable tool (1a), assemble on the main shaft (1b):
   • 1st transmission gear (1c)
   • roller cage (1d)
   • internal race of the bearing (1e)
   • main shaft central bearing (1f)
   NOTE:

   Do not damage the components when using the hydraulic press.

ASSEMBLY OF THE 5TH/6TH TRANSMISSION HUB COMPONENTS 

1. Position the main shaft in a vice.

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2. Install the roller cage (1).

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3. Install the 6th transmission gear (1a) and install the half-rings (1b).
   NOTE:

   Apply Vaseline on the half-rings (1a) to prevent them from slipping or falling.

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4. Install the 5/6 transmission synchronizer ring.

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The standard sizes of the synchronizer keys are the following:

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1. Align the clutch hub alignment marker (1a) with the installation position of the synchronizer hub key (1b).
2. Assemble the sleeve (2a) and hub (2b), securing the ends (2c) of the retaining clips (2d) to the keys to the seats.

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3. Install the 5/6 transmission hub assembly on the shaft and install the sealing ring (1b).
4. Measure the clearance between the sealing ring and the mainshaft groove. The 5/6 gear hub assembly clearance value is 0mm - 0.05mm. If the value of the clearance is not within the specifications, replace the seal ring by choosing the suitable component from those listed in the table:

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1. Install the 5/6 synchronizer ring (1a), aligning the grooves (1b) with the keys (1c) on the 5/6 transmission hub assembly.
2. Install the roller bearing (2) in position and then remove the mainshaft from the vice.