Page 1 of Instructions

Page 2 of Instructions

16. The picture shows where I knocked the screwdriver in.

17. Next is the hardest part of the whole project, removing the triple square bolt from the end of the shaft. Insert the triple square bit into the bolt and give it a solid wack with a hammer before trying to remove. This “shocks” the bolt helping it’s removal.

18. If you have a very strong impact wrench and are lucky, that might work. I’m not that lucky.

19. Here is what I did.

23. Here it is. Drive the set pin (red arrow) out. Wrap a rag around the base of the shaft so the pin doesn’t find it’s way down one of the holes and to depths unknown.

24. DO NOT PULL UP THE FORK AND SLIDER. IF YOU DO A WIRE SPRING AND 3 CLUTCH BLOCKS WILL COME FLYING OUT. (don’t ask and see below).

25. Use a gear puller at the yellow arrow to remove the clutch body from the gear set.

26. The green arrow marks the syncro ring.

27. Here is the clutch body removed.

28. Remove the syncro ring. Be careful as there is another wire spring underneath.

29. Remove the “C” clip.

30. Now grab the entire free 5th gear set, slider & fork and lift at the same time. If done right the wire springs and clutch blocks will stay where they are supposed to.

31. Remove the bolt holding fixed 5th gear. A couple of Phillips head screw drivers stuck through each of the hubs will lock the trans so the bolt can be removed.

32. Use gear puller to remove fixed 5th gear.

33. I used a zip tie to keep the roller bearings in place once everything was removed.

Last Page of Instructions

38. Ok . . . if springs and clutch blocks go flying here is what I did.

39. The red arrow marks the proper orientation of the top spring. The green arrow shows the syncro ring which does Not go there.

40. Once the spring is in place install the syncro ring making sure to line up the 3 keyways of the 5th gear slider with 3 indents on the syncro.

41. Next heat up and install the clutch body and inner race.

42. Install the clutch blocks and hold in place with a zip tie.

43. The bottom spring (look below zip tie) hooks beneath one of the blocks other than the one that is hooked by the top spring and then wraps around under the bottom of the other two blocks.

44. Install the slider and shift fork. On the inside of the slider there are 3 long indents with a shorter indent on either side equally spaced corresponding with the 3 clutch blocks.

45. Once the fork lines up with the hole in the shaft install the set pin.