Disassembly

INPUT SHAFT

DISASSEMBLY
Before disassembly of the input shaft, it is necessary to check the synchronizer stop ring gap. Use a feeler gauge to measure the gaps between the stop rings and the speed gears. The correct gaps are:

^ 1st 0.522 - 2.208 mm (0.021 - 0.087 inch)
^ 2nd 0.522 - 2.208 mm (0.021 - 0.087 inch)
^ 3rd 0.73 - 1.53 mm (0.029 - 0.060 inch)
^ 4th 0.77 - 1.57 mm (0.030 - 0.062 inch).
^ 5th 0.73 - 1.53 mm (0.029 - 0.060 inch)
^ Reverse Brake - 0.505 - 1.74 mm (0.020 - 0.068 inch)

The reverse brake measurement is taken between the stop ring and case.
If a stop ring gap does not fall within the specifications, it must be inspected for wear and replaced. If the 1st or 2nd synchronizer stop ring is worn beyond specifications, the complete output shaft assembly must be replaced.





The input shaft incorporates the 3rd, 4th, and 5th speed gears and synchronizers on the assembly (Fig. 91).





1. Install bearing splitter behind 5th speed gear. Remove snap ring at 5th synchronizer hub on input shaft (Fig. 92).





2. Remove synchronizer and gear using shop press (Fig. 93).





3. Remove caged needle bearing (Fig. 94).





4. Remove 4-5 gears split thrust washer ring (Fig. 95).





5. Remove split thrust washer (Fig. 96).





6. Remove split thrust washer separation pin (Fig. 97).





7. Remove 4th gear (Fig. 98).





8. Remove 4th gear caged needle bearing (Fig. 99). Check the caged needle bearing for a broken retention spring.





9. Remove blocking ring. Remove 3-4 synchronizer hub retaining snap ring (Fig. 100).





10. Install input shaft in shop press. Using bearing splitter, remove 3-4 synchronizer and 3rd gear (Fig. 101).





11. Remove 3rd gear caged needle bearing (Fig. 102). Inspect needle bearing for a broken retention spring
12. Inspect the input shaft for worn or damaged bearing races or chipped gear teeth. Replace as necessary.