Input Shaft

INPUT SHAFT

DISASSEMBLY AND ASSEMBLY

- 2.4L

DISASSEMBLY SERVICE POINTS
<> BALL BEARING REMOVAL

1. Using special tool MD998801, support the ball bearing, and then set them on the press.
2. Push down on the input shaft with the press and extract the ball bearing.

<> THRUST PLATE STOPPER REMOVAL

Using a screwdriver, pry up the position shown in the illustration and remove the thrust plate stopper.

<> 5TH SPEED GEAR REMOVAL

1. Using special tool MD998801, support the 5th speed gear, and then set them on the press.
2. Push down on the input shaft with the press and take off the 5th speed gear.

<> 4TH SPEED GEAR SLEEVE REMOVAL

1. Using special tool MD998801, support the 3rd speed gear, and then set them on the press.
2. Push down on the input shaft with the press and remove the 4th speed gear sleeve.

<> BALL BEARING REMOVAL

1. Using special tool MD9988011, support the ball bearing, and then set them on the press.
2. Push down on the input shaft with the press and extract the ball bearing.

ASSEMBLY SERVICE POINTS
>>A<< OIL SEAL INSTALLATION

Install the oil seal into the illustrated position of the input shaft.

>>B<< BALL BEARING INSTALLATION

1. Using special tool MD998801, support the 2nd speed gear portion of the input shaft, and then set them on the press.
2. Using special tools MD998812, MD998813 and MD998816 or MD998818 , press install the bearing with the press.

>>C<< SNAP RING INSTALLATION

1. Install the thickest snap ring that can be fitted in the snap ring groove of input shaft.
2. Make sure that the ball bearing end play meets the standard value.
Standard value: 0 - 0.12 mm (0 - 0.0047 inch)

>>D-4<

Install the synchronizer spring to the illustrated position of the synchronizer ring and outer synchronizer ring .

>>E<< SYNCHRONIZER RING INSTALLATION

CAUTION: There are 3rd speed and 4th speed synchronizer rings, if the wrong one is installed it will effect the shift feeling.

1. Ascertain whether or not there are identification notches on the synchronizer ring.
Two notches: 3rd speed synchronizer ring
No notches: 4th speed synchronizer ring
2. Install the synchronizer ring so that it does not angle to the cone of the gear.

>>F<< 3RD-4TH SPEED SYNCHRONIZER HUB INSTALLATION

1. Using special tool MD998801, support the 2nd speed gear portion of the input shaft, and then set them on the press.
2. Make sure that the synchronizer ring or inner synchronizer ring has been perfectly matched to the 3rd speed gear cone.
3. Check the installation direction of the 3rd-4th speed synchronizer hub, and put it on the input shaft.
4. Using special tools MD998812, MD998813 and MD998825, press install the 3rd-4th speed synchronizer hub with the press.

5. Make sure that the synchronizer ring or outer synchronizer ring can rotate freely.

>>G<< SYNCHRONIZER SLEEVE INSTALLATION

1. Check the installation direction of the synchronizer sleeve, and install it onto the 3rd-4th speed synchronizer hub.

2. Install the synchronizer sleeve so that the areas with teeth that have raised tips (three areas total) are aligned with the areas on the synchronizer hub that have deep grooves between the teeth (three areas total).

>>H<< 4TH SPEED GEAR SLEEVE INSTALLATION

1. Using special tool MD998801, support the 2nd speed gear portion of the input shaft, and then set them on the press.
2. Using special tools MD998812, MD998813 and MD998824 or MD998825 , press install the 4th speed gear sleeve with the press.

>>I<< 5TH SPEED GEAR INSTALLATION

1. Using special tool MD998801, support the 2nd speed gear portion of the input shaft, and then set them on the press.
2. Using special tools MD998812, MD998813 and MD998824 or MD998825 , press install the 5th speed gear in the input shaft.

>>J<< THRUST PLATE INSTALLATION

1. Install the thickest thrust plates that can be fitted in the groove of input shaft. Install the thrust plate so the surface stamped with the identification mark is facing up.
2. Make sure that the 5th speed gear end play meets the standard value.
Standard value: 0 - 0.09 mm (0 - 0.0035 inch)

>>K<< THRUST PLATE STOPPER INSTALLATION

Install the thrust plate stopper by pressing special tools MD998812, MD998813 and MD998824 or MD998825 by hand. Make sure that it is not tilted.

>>L<< BALL BEARING INSTALLATION

1. Using special tool MD998801, support the 2nd speed gear portion of the input shaft, and then set them on the press.
2. Using special tools MD998812 and MD998818, press install the ball bearing in the input shaft.

>>M<< SNAP RING INSTALLATION

1. Install the thickest snap ring that can be fitted in the groove of input shaft.
2. Make sure that the ball bearing end play meet the standard value.
Standard value: 0 - 0.12 mm (0 - 0.0047 inch)

INSPECTION

INPUT SHAFT

1. Check the outside diameter of the needle bearing mounting portion for damage, abnormal wear and seizure.
2. Check the splines for damage and wear.
3. Check that the helical gear teeth surfaces are not damaged or worn.

NEEDLE ROLLER BEARING
1. Combine the needle roller bearing with the input shaft or bearing sleeve and gear, and check that it rotates smoothly without noise or play.
2. Check the needle roller bearing cage for deformation.

SYNCHRONIZER RING

1. Check the clutch gear teeth for damage and broken.
2. Check internal surface for damage, wear and broken threads.

3. Force the synchronizer ring toward the clutch gear and check clearance "A". If "A" is less than the limit, replace. Minimum limit: 0.5 mm (0.020 inch)

OUTER SYNCHRONIZER RING/INNER SYNCHRONIZER RING/SYNCHRONIZER CONE

CAUTION: When any of the outer ring, inner ring or cone has to be replaced, replace them as a set.

1. Check to ensure that the clutch gear tooth surface and cone surface are not damaged and broken.

2. Install the outer ring, inner ring and cone, press them against the gear, and check clearance "A." If "A" is less than the limit, replace.
Limit: 0.5 mm (0.020 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 splines ends.

SYNCHRONIZER SPRING
Check that the spring is not sagging, deformed or broken,

SPEED GEARS

1. Check that the helical and clutch gear tooth surfaces are not damaged or worn.
2. Check that the synchronizer cone surfaces are not roughened, damaged or worn.
3. Check that the gear inside diameter and front and rear surfaces are not damaged and worn.