Input Shaft

Input Shaft

Special Tool(s):

Disassembly
1. Measure the input shaft clearances.
1 Measure the clearance between the 3rd and 2nd gears. Third gear thrust clearance is 0.05-0.20 mm (0.0020.007 in).
2 Measure the clearance between 4th gear and the bearing cone. Fourth gear endplay is 0.17-0.37 mm (0.0070.014 in).





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

Using the special tool, press off the bearing.
^ Use shaft protector 205-DS004 or equivalent.
^ Discard the bearing.
^ Always install new bearings and cups as a set. Do not install one without the other.





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

Remove 4th gear and the synchronizer blocking ring.





4. Remove and discard the snap ring.





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

Using the special tool, press off the synchronizer hub assembly, the synchronizer blocking ring and 3rd gear as an assembly.
^ Use shaft protector 205-DS004 or equivalent.





6. Disassemble the synchronizer assembly.
1 Remove the synchronizer blocking spring.
2 Remove the opposite synchronize spring.
3 Remove the synchronizer hub inserts.
4 Separate the synchronizer hub from the sleeve.
^ Inspect all synchronizer components for wear and damage. Install a new synchronizer as necessary.





7. Using the special tool, press off the bearing.
^ Use shaft protector 205-DS004 or equivalent.
^ Discard the bearing.
^ Always install new bearings and cups as a set. Do not install one without the other.





8. Measure the input shaft gear runout.
^ Inspect the input shaft for worn or damaged gears. Install a new input shaft as necessary.
^ Input shaft gear runout is 0.05 mm (0.002 in).





9. Set the synchronizer ring squarely in the gear, then measure around the circumference.
^ Measure the clearance from the side of the gear.
- Synchronizer ring clearance is 0.080-1.50 mm (0.031-0.059 in).
^ Inspect for smooth engagement with the gear.
^ Inspect for worn or damaged teeth. Install new components as necessary.





10. 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.

11. Measure the clearance between the 3rd/4th synchronizer hub and its shift fork.
^ Shift fork and hub sleeve clearance is 0.10-0.45 mm (0.0040.017 in).

Assembly

NOTE: Do not reassemble the input shaft dry.

1. Lubricate all input shaft components with the recommended transmission lubricant during reassembly.
2. Using the special tool, press on the new bearing.





3. Install 3rd gear.
4. Assembly the synchronizer.
1 Position the synchronizer hub and sleeve together.
2 Install the synchronizer hub inserts.
3 Install the synchronizer blocking spring.
4 Rotate the synchronizer and install the opposite synchronizer blocking spring.





5. 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 3rd gear when installing the synchronizer hub assembly.

NOTE: Make sure that the 4 grooves in the synchronizer hub are facing the 3rd gear.

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





6. NOTE: Rotate the input shaft.

Install a new snap ring.





7. CAUTION: Press the bearing onto the input shaft by the inner race only. Pressing on the outer race will damage the bearing.

NOTE: Rotate the input shaft.

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

Using the special tools, press on the synchronizer blocking ring, 4th gear and a new bearing.





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

Measure the input shaft clearances.
1 Measure the clearance between the 3rd and 2nd gears.
^ 2nd gear end play is 0.018-0.46 mm (0.007-0.018 in) maximum end play is 0.51 mm (0.020 in).

2 Measure the clearance between the 4th gear and the bearing cone.
^ 4th gear end play is 0.17-0.37 mm (0.007-0.014 in) maximum end play is 0.42 mm (0.017 in).