Input Shaft: Service and Repair

DISASSEMBLY

NOTE: When servicing the input shaft assembly, all snap rings which are removed MUST be replaced with new snap rings upon reassembly. The 5th gear nut must be replaced also.

1. Invert input shaft assembly and place in fixture 8487.





2. Remove input bearing snap ring (Fig. 106).





3. Remove input bearing. Place input shaft assembly onto arbor press table, with the input bearing supported by bearing splitter (Fig. 107). Using adapter 8486-4, press bearing off of shaft, while helper supports shaft to prevent dropping.
4. Place input shaft assembly back into fixture 8487. Secure fixture to bench with fasteners, or secure to bench vise.

NOTE: 5th gear nut is staked to the shaft. If necessary, grind stake area to ease removal, but use care not to contact gear.





5. Remove 5th gear nut with wrench 8478 (Fig. 108). Discard nut and use a new one upon assembly.





6. Remove 5th gear with remover 8486 (Fig. 109).





7. Remove 4th gear (Fig. 110).





8. Remove 4th gear blocker ring (Fig. 111).





9. Remove 3/4 synchronizer snap ring (Fig. 112). Discard and replace with new snap ring upon assembly.





10. Remove 3/4 synchronizer (Fig. 113).





11. Remove 3rd gear blocker ring (Fig. 114).





12. Remove 3rd gear (Fig. 115).

13. Inspect third gear thrust washer for signs of excessive wear. To replace, drive off of input shaft with suitable drift and hammer.

ASSEMBLY

NOTE: When servicing the input shaft assembly, all snap rings MUST be replaced with new ones upon assembly. 5th gear nut must also be replaced.

NOTE: When installing 3/4 synchronizer hub to shaft, make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub journal.

�./:

NOTE: Refer to (Fig. 116) for input shaft assembly reference.

1. Install input shaft into fixture 8487.
2. Install thrust washer if removed upon disassembly.





3. Install 3rd gear (Fig. 117).





4. Install 3rd gear blocker ring (Fig. 118).





5. Install 3/4 synchronizer (Fig. 119). When installing 3/4 synchronizer hub to shaft, make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub journal.





6. Install NEW 3/4 synchronizer snap ring (Fig. 120).





7. Install 4th gear blocker ring (Fig. 121).





8. Install 4th gear (Fig. 122).





9. Install 5th gear and press into position using installer 8481 (Fig. 123).





10. Install NEW 5th gear nut and torque to 200 Nm (148 ft. lbs.) using wrench 8478 (Fig. 124).
11. Stake 5th Gear nut as follows:
a. Install staking tool 8479 to 5th gear nut.





b. Tighten upper thumb screw by hand (Fig. 125).
c. Tighten two (2) side thumb screws by hand.





d. Tighten both staking screws until they bottom on tool body (Fig. 126).





e. Loosen staking screws and thumb screws. Remove tool and visually inspect stake (Fig. 127).

NOTE: The input shaft sealed roller bearing and snap ring do not get installed until transaxle assembly to facilitate installation of the reverse idler gear mechanism.