Disassembly
1. Removal of the ball bearing is shown in Figure 11.84, removal of the reverse gear brake cone sleeve is shown in Figure 11.85, removal of the 5th gear/reverse gear synchronizer hub is shown in Figure 11.86, removal of the 5th gear pinion sleeve is shown in Figure 11.87, removal of the 4th gear pinion sleeve is shown in Figure 11.88. Removal of the ball bearing is shown in Figure 11.89.
Figure 11.84. Removing the ball bearing | 
Figure 11.85. Removing the reverse gear brake cone bushing |
Figure 11.86. Removing the synchronizer hub for 5th gear/reverse gear | 
Figure 11.87. Removing the 5th gear bushing |
Figure 11.88. Removing the 4th gear bushing | 
Figure 11.89. Removing the ball bearing |
Assembly
Snap ring
2. Select and install the snap ring so that the axial clearance of the front bearing of the primary shaft corresponds to the required one (Figure 11.91). The required clearance is: - 0.01 to 0.12 mm.
Figure 11.90. Checking the axial clearance of the front bearing of the primary shaft
3rd and 4th gear synchronizer hub
3. Install the hub of the 3rd and 4th gear synchronizer (Figure 11.91). When installing the hub, make sure that the synchronizer locking ring does not get jammed (Figure 11.92).
Figure 11.91. Install the 3rd and 4th gear synchronizer hub | 
Figure 11.92. When installing the hub, make sure that the synchronizer locking ring does not get jammed |
Synchronizer clutch
4. Install the synchronizer sleeve (Figure 11.93).
Figure 11.93. Install the synchronizer clutch
5. When installing the synchronizer sleeve, the deep part of the groove on the synchronizer hub must align with the protruding part of the sleeve (Figure 11.94).
Figure 11.94. When installing the synchronizer sleeve, the deep part of the groove on the synchronizer hub must align with the protruding part of the sleeve
Snap ring
6. Select and install a snap ring such that the axial clearance of the front bearing of the primary shaft will correspond to the required one (Figure 11.95). The required clearance is: - 0.01 to 0.09 mm.
Figure 11.95. Installing the snap ring and checking the axial clearance of the front bearing of the primary shaft
Examination
Primary shaft
7. Check the outer surface under the needle bearing for damage, excessive wear and corrosion. Check the splines for damage and wear (Figure 11.96).
Figure 11.96. Inspect the outer surface under the needle bearing for damage, excessive wear and corrosion. Inspect the splines for damage and wear
Synchronizer locking ring
8. Check the clutch gear toothed surface for damage or breakage. Make sure that the inner part of the cone and the threaded part are not damaged or worn (Figure 11.97).
Figure 11.97. Check for damage or breaks on the toothed surface of the clutch gear
9. Press the synchronizer locking ring against the gear and check the gap A (Figure 11.98). Replace the part if the measured gap exceeds the permissible one. Permissible gap: 0.5 mm.
Figure 11.98. Press the synchronizer locking ring against the gear and check the clearance A