Disassembly
1. Remove the tapered roller bearing, the fourth pinion of the input shaft, the spacer ring, the third pinion of the secondary shaft, the second gear assembly with the second gear sleeve and the needle roller bearing, the first gear assembly with the needle roller bearing and sleeve and the steel ball. Use the special tool (09432-33200).
2. Using the special tool, remove the rear tapered roller bearing.
Warning: The bearing cannot be reused after being removed from the shaft.
Examination
Secondary shaft
1. Check the outer surface of the secondary shaft where the needle bearing is installed for damage or excessive wear (area A).
2. Check the splines for wear and damage.
Needle bearing
1. Install the needle bearing onto the shaft with the sleeve and gear. The bearing should rotate smoothly without excessive noise or play.
2. Check the bearing separator for deformation.
Synchronizer ring
1. Check the clutch teeth for damage.
2. Check the inner surface for damage or wear of the grooves.
3. Press the synchronizer ring in the direction of the clutch and check the gap "A". If the gap value does not correspond to the required value, replace it.
- Limit value - 0.5 mm
Synchronizer hub and cage
1. Install the synchronizer sleeve onto the hub and check for smooth sliding.
2. Check the clip for wear.
3. Check the end surfaces (in contact with the gears) of the hub for wear.
Warning: When replacing the hub, the race must also be replaced.
Synchronizer key and spring
1. Check the synchronizer key center projection for wear.
[The original text is available on the website: hyundaibook]
2. Check the spring for weakening, deformation or damage.
Gears
1. Check the helical gear and clutch teeth for damage and wear.
Assembly
1. The shaft unit is assembled in the reverse order of disassembly.