Mainshaft (three-speed synchromesh type)	dismantling and reassembly
	Baulk ring synchromesh replaced the early cone type on Mk I models from engine No 8AM-U-H412992. The dismantling procedure is similar for both types except that the second and thirdlfourth gear synchronisers are not fitted with baulk rings. Any other differences will be stated where necessary.
	With the mainshaft assembly laid out on a clean, uncluttered working surface, begin dismantling by sliding off the first speed gear, hub and baulk ring from the rear end of the mainshaft.
	Now slide the third/fourth gear synchromesh hub and baulk rings off the front end of the mainshaft.
	Using a thin screwdriver or piece of thin rod, press down the spring-loaded plunger and turn the splined thrustwasher so that a spline holds the plunger down and the thrustwasher is so positioned that it can now be slid off the front of the mainshaft.
	Now lift out the plunger and spring and slide out the third speed gear and on later models, the needle roller bearings.
Early models:	Withdraw the third gear bush and interlocking ring, followed by the second speed gear and bush and then the rear thrustwasher.
Later models:	Using two thin screwdrivers or two pieces of thin rod, depress the spring-loaded plungers and have an assistant turn the splined thrustwasher so that the splines hold the plungers down and the thrustwasher is so positioned that it can now be slid off the rear of the mainshaft. Now take out the two split collars, slide the second speed gear off the rear of the mainshaft and retrieve the needle roller bearings, spring and plungers.
	All models: Should it be necessary to dismantle the synchro-hubs, place a rag around the hub to catch the steel balls that will be ejected as the hub is separated. Now push the inner part of the hub out of the collar and collect the three balls and springs from the rag. If the first/second speed gear hub has been dismantled also retrieve the plunger from the centre of the gear hub.
	Begin reassembly by first rebuilding the synchro-hubs if they were previously dismantled. Place the springs and balls into the centre of the hub (photo) and hold them in position while an assistant firmly pushes the hub into the collar. When reassembling the first/second speed hub ensure that the plunger hole in the hub aligns with the cutaway in the collar (Fig. 6.3) and that the tapered ends of the gear teeth are on the same side as the raised centre boss in the hub.
Early models:	When fitting new bushes to the mainshaft, heat then in an oven to approximately 356deg to 392deg G (180 to 200deg C) and slide them onto the mainshaft hot. When they cool the subsequent contraction will ensure a secure fit on the mainshaft. Slide on the rear thrustwasher followed by the second gear bush, plain side towards the thrust-washer. Now fit the second speed gear with the synchro-cone towards the rear of the shaft and then the interlocking ring. Ensure that the notches on the interlocking ring engage with the dogs on the second gear bush. Slide on the third gear bush, engaging the dogs with the interlocking ring and then refit the third speed gear, plain side first.
Later models:	Position the second speed gear roller bearings on the mainshaft and hold them in place with liberal amounts of medium grease (photo). Refit the spring and plungers into the drilling on the mainshaft (photo) and then slide on the second speed gear, flat side first from the rear of the mainshatt. Depress the plungers and position the gear over the needle roller bearings (photo). Place the two split collars in position and refit the splined thrustwasher (photos). Depress the spring-loaded plungers, push down on the thrustwasher and then turn it slightly until the plungers are heard to click into place and lock the thrustwasher. Position the third speed gear needle roller bearings on the mainshaft using liberal amounts of grease to hold them in place and then slide on the third speed gear from the front of the mainshaft, flat side first (photo).
All models:	Refit the spring and locking plunger to the mainshaft (photo). Slide the thrustwasher over the front of the shaft, depress the plunger, push down on the thrustwasher and turn it slightly until the plunger can be heard to click into place and lock the thrustwasher (photo).
	Fit the locking peg to the drilling in the first/second synchro-hub (photo), place the baulk ring over the cone of the second speed gear (photo) and slide the synchro-hub onto the mainshaft with the raised boss of the hub facing rearwards (photo). Ensure that the dogs on the baulk ring engage with the slots in the hub.
	Now place the third gear baulk ring over the cone of the third speed gear (photo) and then slide on the third/fourth synchro-hub with the raised boss of the hub facing forward (photo). Mainshaft reassembly is now complete.