M5040, M6040, M7040, WSM
1st Shaft Assembly
1. Remove the bearing (1) and external circlip (2).
2. Draw out the 1st-2nd synchronizer unit and gears.
3. Remove the bearing (25).
4. Draw out the 3rd-4th synchronizer unit and gears.
(When reassembling)
• Be sure to assemble the synchronizer unit, set the teeth (28) on
the shifter (6) to the key (7) as shown in the figure.
• The directionality of couplings.
- Hydraulic shuttle model :
The both coupling (29) and (30), turn the longer boss side (D)
to the forward (F).
- Synchro shuttle model :
The coupling for 1-2 speed (31), turn the longer boss side (D)
to the rearward (R).
The coupling for 3-4 speed (32), turn the longer boss side (D)
to the forward (F).
• Apply transmission fluid to synchronizer unit.
• Apply molybdenum disulfide (Three Bond 1901 or equivalent) to
the inner race (23).
• Face the grooved side of thrust collar (24) to the gear side.
• Replace the external circlip (2) with new one.
• Adjust the side clearance (L) between external circlip (2) and
adjusting collar (3). Check the clearance (L).
clearnace L for hydraulic shuttle model only.)
(Reference)
• Thickness of adjusting collar.
1.5 mm (0.059 in.)
1.7 mm (0.066 in.)
Clearance (L)
Factory spec.
3-S38
TRANSMISSION
1.9 mm (0.075 in.)
2.1 mm (0.082 in.)
Less than 0.2 mm
(Adjust the
0.0078 in.
KiSC issued 06, 2008 A