Input Shaft
DISASSEMBLY
Follow disassembly steps outlined in illustration.
Disassembly Service Points
Front Taper Roller Bearing Removal
Bearing Sleeve For 5th Speed Gear Removal
INSPECTION
Input Shaft
1. Check the outer surface of the input shaft where the needle bearing is mounted for damage, abnormal wear and seizure [portion A].
2. Check the splines for damage and wear.
Needle Bearing
1. Combine the needle bearing with the shaft or bearing sleeve and gear, and check that it rotates smoothly without abnormal noise or play.
2. Check the needle bearing cage for deformation.
REASSEMBLY
Reassembly in reverse order as disassembly.
Reassembly Service Points
>A< 3rd-4th Speed Synchronizer Hub / 3rd-4th Speed Synchronizer Sleeve Installation
>B< Synchronizer Spring / Synchronizer Key Installation
Position each spring with respect to the keys as illustrated.
>C< Bearing Sleeve For 4th Speed Gear Installation
>D< Sub Gear / Cone Spring / Snap Ring Installation
>E< Rear Taper Roller Bearing Installation
>F< Snap Ring Installation
Select the thickest snap ring that can be fitted in the snap ring groove.
Standard value:
Input shaft rear bearing end play 0-0.09 mm (0-0.0035 inch)
CAUTION:
1. Do not reuse the snap ring.
2. Do not open the snap ring too wide by pliers, or the sleeve will be improperly installed.
>G< Bearing Sleeve For 5th Speed Gear Installation
CAUTION: When press-fitting the sleeve to the input shaft, make sure that the sleeve flange is closely fitted to the bearing.
>H< Front Taper Roller Bearing Installation
Synchronizer Ring
1. Check the clutch gear teeth for damage and breakage.
2. Check the internal surface for damage, wear and broken threads.
3. Force the synchronizer ring toward the clutch gear and check clearance "A". Replace if it is out of the limit.
Limit: 0.5 mm (0.02 inch)
Synchronizer Sleeve And Hub
1. Combine the synchronizer sleeve and hub, and check that they slide smoothly.
2. Check that the sleeve is free from damage at its inside front and rear ends.
3. Check for wear of the hub end surfaces (in contact with each speed gear).
CAUTION: Replace the synchronizer hub and sleeve as a set.
Synchronizer Key And Spring
1. Check for wear of the synchronizer key center protrusion.
2. Check the spring for weakness, deformation and breakage.
Speed Gears
1. Check the synchronizer cone for rough surface, damage and wear.
2. Check the gear bore and front and rear ends for damage and wear