Special Tools

1. Detach 1st gear (4).

•	Press 1st gear off main shaft with KM-307-B  (2) and KM-736  (1)

•	Remove gear wheel, 1st gear, and thrust washer (3)

2. Detach 3x synchronizer ring, gear wheel, 1st gear.

Remove needle bearing, inner synchronizer ring (5), intermediate ring (6) and outer synchronizer ring (7).

3. Remove synchro body retaining ring.

•	Remove needle bearing

•	Remove retaining ring synchro body 1st/2nd gear using KM-396  (8)




4. Detach 2nd gear.

•	Press synchro body assembly 1st/2nd gear and gear wheel for 2nd gear (1) off main shaft with KM-307-B and KM-736

•	Remove shift sleeve 1st/2nd gear (2), outer synchro ring (3), intermediate ring (4) and inner synchro ring (5) from gear wheel (6) of 2nd gear and needle bearing

5. Detach thrust washer halves (arrows).

•	Remove retaining ring (7)

•	Detach thrust washer halves

6. Remove 3rd gear gearwheel (8).
7. Remove retaining ring synchro body 3rd/4th gear.

•	Remove 2x slotted needle bearings (9)

•	Remove 3rd gear (10) synchronizer ring

•	Remove retaining ring synchro body 3rd/4th gear using KM-396  (11)

•	Remove spacing ring from synchro body




8. Detach 4th gear.

•	Press off gear wheel, 4th gear (4), and synchro body with KM-307-B

•	Remove synchro body 3rd/4th gear assembly (2), synchro ring 4th gear (3) from 4th gear

Important: Open needle bearing

9. Detach needle bearing (5).

Remove 2x slotted needle bearings from main shaft.

10. Clean all parts.

Important: If gears are damaged, always check the gears of the gear cluster and replace gear cluster if necessary.

11. Check all parts for damage. Replace damaged components.