M/T Mainshaft Reassembly

Exploded View
Special Tools Required
NOTE: Refer to the Exploded View as needed during this procedure.
  1. Clean all the parts in solvent, dry them, and apply lubricant to all contact surfaces except the 3rd/4th and 5th/6th synchro hubs.
  1. Install the needle bearing and 3rd gear on the mainshaft.
  1. Install the double cone synchro assembly (A) by aligning the synchro cone fingers (B) with the holes in 3rd gear (C), then install the synchro spring (D).
  1. Install the 3rd/4th synchro hub (A) by aligning the synchro cone fingers (B) with the grooves in the 3rd/4th synchro hub (C).
  1. Install the 3rd/4th synchro hub (A) using the driver, 40 mm I.D. (B).
  1. Install the 3rd/4th synchro sleeve (A) by aligning the stops (B) with the 3rd/4th synchro sleeve and hub. After installing, check the operation of the 3rd/4th synchro hub set.
  1. Install the synchro spring (A).
  1. Install the double cone synchro assembly (B) by aligning the synchro cone fingers (C) with the grooves in the 3rd/4th synchro hub (D).
  1. Install 4th gear (A) by aligning the synchro cone fingers (B) with the holes in 4th gear (C).
  1. Install the needle bearings, distance collar, 5th gear, and the 5th gear synchro spring and ring.
  1. Install the 5th/6th synchro hub (A) by aligning the synchro cone fingers (B) with the grooves in the 5th/6th synchro hub (C).
  1. Install the 5th/6th synchro hub (A) using the driver, 40 mm I.D. (B), attachment, 30 mm I.D. (C).
  1. Install the 5th/6th synchro sleeve.
  1. Install the synchro spring (A).
  1. Install the synchro ring (B) by aligning the synchro cone fingers (C) with the grooves in the 5th/6th synchro hub (D).
  1. Install the 6th gear distance collar, needle bearing, and 6th gear.
  1. Install the new ball bearing (A) using the driver, 40 mm I.D. (B), attachment, 30 mm I.D. (C) and press (D).