Disassembly
1. Before removing parts from the secondary shaft, measure the axial clearance of the driven gears of 1st, 2nd, 3rd and 4th gears. The clearance values are given in the section "Data for adjustments and control". If the clearance is not within the specified limits, disassemble the shaft and inspect the contact surfaces of the gear, shaft and synchronizer hub. Then check the clearance between the half rings and the shaft groove.
2. Press off the front bearing of the secondary shaft.
3. Press out the secondary shaft rear bearing using the same tools as for the front bearing.
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4. Remove the half ring holder, half rings and thrust sleeve.
5. Press off the 5th gear driven gear.
6. Remove the 4th gear driven gear, its bushing and the steel ball. Be careful not to lose the ball.
7. Remove the 3rd and 4th gear synchronizer, 3rd gear driven gear, 2nd and 3rd gear gear sleeve, ball and 2nd gear driven gear.
8. Remove the 1st and 2nd gear synchronizer, 1st gear driven gear and needle bearing.
Examination
See section "Primary shaft".
Assembly
1. Assemble the 1-2 and 3-4 gear synchronizers. Note that the ends of the return springs must engage different crackers.
2. Install the needle bearing and 1st gear driven gear.
3. Press the 1st and 2nd gear synchronizer onto the shaft using the ST22452000 mandrel.
4. Install the steel ball, 2nd driven gear, 2nd and 3rd gear bushing, 3rd driven gear and press on the 3rd and 4th gear synchronizer using the ST37750000 drift. Before installing the ball, lubricate it with multi-purpose grease. The 2nd and 3rd gear bushing has a groove; which the ball should fit into.
5. Install the ball, bushing and 4th gear driven gear.
Before installing the ball, lubricate it with a universal grease. The 4th gear driven gear bushing has a groove into which the ball should fit.
6. Press on the 5th gear driven gear using tool ST37750000.
7. Install the thrust sleeve.
8. Install the half rings, selecting them so that the gap between the ring and the groove is 0-0.1 mm. Available ring sizes are given in the section "Data for adjustments and maintenance".
9. Install the half ring holder.
10. Press the rear bearing onto the secondary shaft using the ST22360002 mandrel.
11. Press on the front bearing.
12. Measure the axial clearances of the gears (see subsection "Disassembly").