Main Shaft Disassemble NV4500

1. Remove the 4TH speed gear clutch gear.



2. Remove the main drive gear thrust bearing.
3. Remove the 4TH speed gear synchronizer ring.



4. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to replace the parts in the same position.

Important: Do not remove the sleeve from the synchronizer hub.




5. Remove the 3RD speed gear and the 3--4 synchronizer assembly. Use a two-jaw puller. Place the puller jaws behind the 3RD speed gear clutching teeth.



6. Remove the following parts:

6.1.	The 3RD speed gear bearing

6.2.	The spacer




7. Remove the following parts

7.1.	The 2ND speed gear retainer ring

7.2.	The thrust washer

7.3.	The thrust washer retainer pin




8. Remove the 2ND speed gear.



9. Remove the 2ND speed gear bearing.



10. Remove the 2ND speed gear synchronizer retainer ring.



11. Remove the 2ND speed gear synchronizer rings.



12. Remove the 1--2 synchronizer sleeve retainer ring.



13. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to replace the parts in the same position.

Important: Do not remove the sleeve from the synchronizer hub.




14. Remove the 1--2 synchronizer assembly.



15. Remove the 1ST speed gear synchronizer retainer ring.



16. Remove the following parts

16.1.

The 1ST speed gear synchronizer rings

16.2.

The clutch gear retainer ring

16.3.

The clutch gear

17. Turn the mainshaft over.



18. Remove the rear mainshaft bearing. Use a hydraulic press and a suitable gear puller.



19. Remove the reverse gear thrust washer.



20. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to replace the parts in the same position.

Important: Do not remove the sleeve from the synchronizer hub.




21. Remove the reverse gear and synchronizer assembly from the mainshaft.



22. Remove the reverse gear bearing and spacer.
23. Remove the reverse gear clutch gear retainer ring.
24. Remove the reverse gear synchronizer ring and the clutch gear.



25. Remove the 1ST speed gear and the bearing.

Main Shaft Disassemble NV3500 4WD

Tools Required

Important: Do not remove the sleeve from the synchronizer hub. The sleeve prevents the detent balls from popping out.




1. Remove the mainshaft snap ring.



2. Remove the 3rd/4th speed gear synchronizer and the 3rd speed gear. Use tool J 22912-01 and a hydraulic press.



3. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.



4. Remove the 3rd speed gear needle bearing assembly.



5. Remove the following components:

5.1.	The 2nd speed gear thrust washer retainer ring

5.2.	The 2nd speed gear 2-piece thrust washer




6. Remove the 2nd speed gear.



7. Remove the 2nd speed gear needle bearing assembly.



8. Remove the following synchronizer parts:

8.1.	The reaction cone

8.2.	The synchronizer cone

8.3.	The blocker ring

8.4.	The interim ring

Important: Do not remove the sleeve from the synchronizer hub. The sleeve prevents the detent balls from popping out.




9. Remove the mainshaft snap ring.



10. Remove the 1st speed gear and the 1st/2nd speed gear synchronizer.

Use tool J 22912-01 and a hydraulic press.




11. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.



12. Remove the following synchronizer parts:

12.1.

The blocker ring (1)

12.2.

The synchronizer cone (2)

12.3.

The reaction cone (3)

12.4.

The interim ring (4)




13. Remove the 1st speed gear needle bearing assembly.



14. Remove the 5th speed gear.



15. Remove the 5th speed gear needle bearing assembly.

Important: Do not remove the sleeve from the synchronizer hub. The sleeve prevents the detent balls from popping out.




16. Remove the mainshaft snap ring.



17. Remove the reverse speed gear and the 5th/Reverse speed gear synchronizer assembly. Use tool J 22912-01 and a hydraulic press.



18. Scribe a mark on the synchronizer hub and on the sleeve. This will help you to reinstall the parts in the same position.



19. Remove the reverse speed gear needle bearing assembly.



20. Remove the drag seal from the mainshaft.



21. Remove the drag seal from the reverse speed gear.