ZEST BOLT Service Manual

DRIVETRAIN C549 33 8. Remove the 1st-2nd and reverse sliding sleeve. Hub (1a), the 1st speed synchronizer ring assembly (1b) and 1st speed drive gear (1c) using tools (1d)287458902606(Extractor) and (1e) 287458902608 (Clamps). 9. Remove the needle bearing (2). 10.Move the lay shaft front bearing inner race, as necessary, using a special chisel. 11.Remove the inner race of the lay shaft front bearing using the tools 287458902604 (Strut) and287458902615 (Clamps). NOTE: If the lay shaft front bearing inner race has to be replaced and cannot be removed, replace it together with the lay shaft. E. MAINSHAFT- DISMANTLING 1. Move the main shaft front bearing, as necessary, by applying a special chisel to the inner race. 2. Remove the main shaft front bearing (1a) using tools (1b) 287458902604 (Strut) and (1c) 287458902615 (Clamps). 3. Remove rear bearing (1a), shim (1b), 4th speed drive gear (1c), 4th speed drive gear needle bearing (1d), 4th speed drive gear bush (1e), 3rd and 4th speed sliding sleeve (1f), pre- synchronizer pads (1g) for the 3rd and 4th speed sliding sleeve hub, 4th speed synchronizer ring (1h), hub for the 3rd and 4th speed sliding sleeve (1i), 3rd speed synchronizer ring (1l) and third speed drive gear (1m) using tools (1n) 287458902606 (Extractor) and (1o) 287458902608 (Clamps). 4. Remove the needle bearing for the 3rd speed drive gear. 5. Proceed with washing and checking the condition of all the components