Input Shaft Assemble

Input Shaft Assemble

Tools Required

* 78 41 067 Sleeve Inner Driver
* 87 91 204 Output Shaft Bearing Race Sleeve
* 87 91 261 Output Shaft Remover
* 87 92 202 Output Shaft Bearing Race Sleeve





Important: Lubricate all rotating parts and bearings with manual transaxle lubricant P/N 21018899 during assembly.

Important: Install the hub with the synchronizer hub washer groove facing towards 87 92 202 and away from the 3rd gear blocking ring.

1. Install the leaf springs on the 3rd gear blocker ring and install into the 3rd/4th gear synchronizer hub. Align the blocker ring lugs in the gaps of the synchronizer hub.

Important: Ensure that the leaf springs and 3rd gear blocker ring do not move out of proper position while seating the input shaft on 3rd/4th gear synchronizer.

2. Secure 87 92 202 in a vice. Assemble 3rd/4th gear synchronizer hub, leaf springs, blocker ring and 3rd drive gear and bearings on top of 87 92 202 and install the input shaft.




3. Install the 3rd/4th gear synchronizer hub washer and retaining ring. The square edge on the retaining ring faces up, towards 4th gear.
4. Measure the clearance between the 2nd and 3rd drive gears.

The 2nd gear to 3rd gear clearance is 0.05-0.4 mm (0.001-0.015 in).




5. Install the 3rd/4th gear synchronizer springs and pins.





Important: The tall teeth on the 3rd/4th synchronizer sleeve must align with the deep tooth gaps in the synchronizer hub.

6. Install the 3rd/4th synchronizer sleeve onto the synchronizer hub.





Important: Do not move the synchronizer sleeve after installing detent inserts. The inserts will not stay in position if the sleeve is moved. Only move the sleeve after installing the 4th drive gear.

7. Move the 3rd/4th gear synchronizer sleeve down, towards 3rd gear, far enough to install the synchronizer detent inserts. Use a small screwdriver to depress the pins and springs, and install the detent inserts.




8. Install the 4th gear blocking ring and leaf springs to the synchronizer hub.
9. Install the 4th gear bearing assembly and the 4th drive gear.
10. Hold down the 4th gear and move the synchronizer sleeve up and down to check for proper operation.




11. Press on the new input shaft bearing, next to the 4th drive gear, using the 78 41 067. Support the shaft under the 2nd drive gear.





Notice: When installing a new bearing retaining ring, open the ring only as far as necessary to fit the ring over the shaft. Opening the ring too far will damage it.

12. Install a new bearing retaining ring. Make sure the chamfered edge on the ring is facing up, away from the bearing.




13. Measure the clearance between the 4th drive gear and input shaft bearing.

The 4th gear to input shaft bearing clearance is 0.02-0.4 mm (0.001-0.015 in).




14. Press on the NEW input shaft bearing, next to the 1st drive gear, using the sleeve from the 87 91 261 (1).