120
Front Section Disassembly
4
Front Section 2nd Ed. 02/07 FSO-2405
FSO-2405/103
121314
15
Mainshaft
10. Use two tubular tools and press the late
installed set of components of the mainshaft.
Make sure to align the synchronizer ring lugs
with hub key slots.
WARNING! Apply force to bearing inner
race. NEVER apply force to the bearing
cage.
Do NOT use the shaft flange as a
pressing base.
NOTE: See “Special Tools”, Ref. E010001,
E010002.
11. Make sure the pressing procedure was
successfully: disengage the synchronizer and
position it between the 1st and 2nd speed
gears. In this condition, the gears should run
free.
12. Turn the mainshaft over and install the 3rd
speed gear needle bearing.
NOTE: The 3rd speed gear needle bearing
was modified. When servicing the unit,
replace the old needle bearing by the new
one.
Old part: 239818 / New part: 3348857
They are interchangeable.
13. Install the 3rd speed gear.
14. Install the 3rd speed synchronizer ring.
NOTE: The 1st, 2nd, 3rd and 4th speed have
equal synchronizer rings and they are all
EFM II coated.
15. Install the 3rd/4th speed synchronizer
assembly. Make sure it is installed in the proper
position.
WARNING! Both the 3rd/4th synchronizer
sleeve largest chamfer and the hub most
prominent side must face the 3rd speed
gear (see “Synchronizer Assemblies”).
The 1st/2nd synchronizer hub does have
the anti-escape relief, which must face the
3rd speed gear (see “Synchronizer
Assemblies”).
FSO-2405/165
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10
FSO-2405/166
FSO-2405/163
Old New
Needle bearing
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