D. Input Shaft Overhaul

REMOVE OR DISCONNECT

^ Tool Required:
- J 22912-01 Split Plate

NOTICE: Observe the hydraulic pressure gage during input shaft disassembly. Pressure on the input shaft or its components should not exceed 4990 kg (11,000 lbs.). If pressure higher than specified is needed for input shaft disassembly, the input shaft may be misaligned in the press support. Reset the press and press support before resuming input shaft disassembly or damage to the input shaft and its components may occur.

Important
- In order to avoid placing undue stress on gear teeth during removal, invert the J 22912-01 so that the flat side of the J 22912-01 is facing upward when disassembling the input shaft assembly.





1. Right input shaft bearing from the input shaft using a J 22912-01 and a press arbor.





2. 5th gear spacer, left input shaft bearing and input shaft 4th gear from the input shaft simultaneously using the J 22912-01 and a press arbor.
3. 3rd and 4th gear bearing and high speed synchronizer ring from the input shaft.





4. High speed synchronizer snap ring from input shaft.





5. High speed sleeve and hub with high speed synchronizer ring and input shaft 3rd gear from input shaft using the J 22912-01 and a press arbor.
6. 3rd and 4th gear bearing from input shaft.
7. High speed sleeve from high speed hub.
8. High speed synchronizer spring from high speed hub.

Clean
- All components with clean solvent and dry thoroughly.

Inspect
- Input shaft for flat spots, excessive wear or damage. Replace as necessary.





- Input shaft oil passages for obstructions by applying compressed air into the end of the input shaft. If air does not flow freely out of the input shaft oil passages, replace the input shaft.
- All bearings for roughness, locking or damage. Replace as necessary.
- All gears for cracks, chipped or broken teeth or other damage. Replace as necessary.
- All synchronizer components for chipped or broken teeth, excessive wear or damage. Replace as necessary.





Measure
1. Clearance between the input shaft 4th gear and high speed synchronizer ring and gear using a feeler gage. Standard clearance is 1.0 to 1.4 mm (0.039 to 0.055 inch). If clearance is below 0.5 mm (0.019-inch), replace the high speed synchronizer ring and input shaft 4th gear.
2. Clearance between the input shaft 3rd gear and high speed synchronizer ring and gear using a feeler gage. Standard clearance is 1.0 to 1.4 mm (0.039 to 0.055 inch). If clearance is below 0.5 mm (0.0 19 inch), replace the high speed synchronizer ring and input shaft 3rd gear.
3. Clearance between the input shaft 5th gear and 5th speed synchronizer ring and gear using a feeler gage. Standard clearance is 1.0 to 1.4 mm (0.039 to 0.055 inch). If clearance is below 0.5 mm (0.0 19 inch), replace the 5th speed synchronizer ring and input shaft 5th gear.

INSTALL OR CONNECT

^ Tools Required:
- J 34844 Transaxle Shaft Bearing Installer
- J 36850 Transjel Transmission Assembly Lubricant
- J 35283 Input Gear Bearing Installer

1. Apply a thin coat of J 36850 to all parts prior to assembly.





2. High speed synchronizer springs to the high speed hub.
3. High speed sleeve onto the high speed hub.
4. 3rd and 4th gear bearing onto input shaft.





5. Input shaft 3rd gear, high speed synchronizer ring and high speed sleeve and hub onto input shaft using a J 35283 and a press arbor.

Important
- When pressing the high speed sleeve and hub onto the input shaft, make sure the synchronizer keys are aligned with the keyways in the high speed hub.

Inspect
- Input shaft 3rd gear for smooth rotation after high speed sleeve and hub installation. If input shaft 3rd gear does not rotate smoothly, remove and reinstall until smooth rotation is obtained.





6. High speed synchronizer snap ring onto input shaft.
7. 3rd and 4th gear bearing and high speed synchronizer ring onto input shaft.

Important
- To prevent distortion of the 5th gear spacer upon installation, install the input shaft 4th gear and left input shaft bearing first, then install the 5th gear spacer separately.





8. Input shaft 4th gear and left input shaft bearing simultaneously using a J 34844 and a press arbor, then the 5th gear spacer onto the input shaft using the J 34844 and a press arbor.





9. Right input shaft bearing onto the input shaft using the J 34844.