Input Shaft

Input Shaft








Special Tool(s)

Disassembly








CAUTION: When pressing off components, hold the shaft so that it does not fall.





1. Measure the input shaft clearances.
1. Measure the clearance between the third and second gears.
2. Measure the clearance between fourth gear and the bearing cone.





2. Using the special tools and a press, press off the bearing (fourth gear end).





3. CAUTION: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.

Remove fourth gear and the synchronizer blocking ring.





4. Remove the snap ring.





5. CAUTION: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.

NOTE: Inspect all the synchronizer components for wear and damage.

Using the special tools and a press, press off the synchronizer hub assembly, synchronizer blocking ring, and third gear.





6. Using the special tools and a press, press off the bearing (third gear end).





7. Measure input shaft gear runout.
^ Inspect the input shaft for worn or damaged gears.





8. NOTE: Set the synchronizer ring squarely in the gear, then measure around the circumference.

Inspect the synchronizer blocking rings.
^ Measure the clearance from the side of the gear.
^ Inspect for smooth engagement with the gear.
^ Inspect for worn or damaged teeth or tapper surface.
9. Inspect the synchronizer hub.
^ Inspect for worn or damaged splines, synchronizer insert groove or end surface.
^ Inspect for smooth hub sleeve movement when it is installed.





10. Measure the clearance between the third/fourth synchronizer hub and its shift fork.

Assembly





1. NOTE: Whenever a bearing has been removed, a new one must be installed.

Using the special tools and a press, press on the bearing (third gear side).
2. Install the third gear.





3. NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove and synchronizer hub inserts.

NOTE: Make sure to have the ridge facing the third gear when installing the synchronizer hub assembly.

NOTE: Make sure that the four grooves in the synchronizer hub are facing the third gear.

Using the special tools and a press, press on the synchronizer blocking ring and synchronizer hub assembly.





4. Install the snap ring.





5. NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove and synchronizer hub inserts.

Using the special tools and a press, press on the synchronizer blocking ring, fourth gear, and the bearing.





6. NOTE: If not within specifications, disassemble and reassemble the input shaft assembly.

Measure the input shaft clearances.
1. Measure the clearance between the third and second gears.
2. Measure the clearance between the fourth gear and the bearing cone.