Input Shaft: Service and Repair
Disassembly
1. Remove the snap ring(A) and remove the front ball bearing(B) using press.
2. After removing the snap ring, remove the rear ball bearing (A) by using press.
3. Remove the spacer (A) and snap ring (B).
4. Remove the 5th sleeve, 5th gear, 4th gear, 3&4th sleeve and 3rd gear all together using press.
Inspection
Input Shaft
1. Check the outer surface of the input shaft where the needle bearing is mounting for damage or abnormal wear.
2. Check the input shaft gear teeth for damage.
Needle Bearing
1. Install the needle bearing on the shaft with the bearing sleeve and gear.
Check that it rotates smoothly without abnormal noise or play.
2. Check the needle bearing cage for distortion.
Synchronizer Ring
1. Check the clutch gear teeth for damage.
2. Check the internal surface for damage, wear or broken grooves.
3. Push the synchronizer ring toward the clutch gear and check clearance "A".
Replace if it is not within specifications.
Limit "A" : 0.02in (0.5mm)
Synchronizer Sleeve And Hub
1. Install the synchronizer sleeve on the hub and check that it slides smoothly.
2. Check that the sleeve is free from damage.
3. Check for wear of the hub end surfaces (in contact with each gear).
NOTE:
Replace the synchronizer hub and sleeve as a set.
Synchronizer Key
1. Check for wear of the synchronizer key center protrusion.
2. Replace the synchronizer key assembly.
Gears
1. Check the bevel gear and clutch gear teeth for damage or wear.
2. Check the gear bore for damage or wear.
Reassembly
1. Install the 3rd needle bearing(A) on the input shaft(B).
2. Apply MT oil to the needle bearing.
3. Install the 3rd gear(A).
4. Install the 3rd inner synchronizer ring(A). (Double cone type)
5. Install the 3rd synchronizer cone(B).
6. Install the 3rd outer synchronizer ring(C).
NOTE:
Pay attention the direction of protrusion of a synchronizer ring.
7. Assemble the 3rd&4th synchronizer hub(A) using press.
NOTE:
- When installing the synchronizer hub, make sure that the fingers of synchronizer ring are seated correctly in its groove on the synchronizer hub.
- After installation of the synchronizer hub, check that sychronizer hub rotates smoothly.
8. Install the synchronizer keys(A).
9. Install the 3rd&4th synchronizer sleeve.
NOTE:
- Put down the 3rd slope face of sleeve with the identification mark.
- Make sure that the groove of sleeve inside is seated correctly in the groove of synchronizer hub.
10. Install the 4th outer synchronizer ring(A). (Double cone type)
NOTE:
When installing the synchronizer ring, make sure that the fingers of synchronizer ring are seated correctly in the grooves of the 3rd&4th synchronizer hub.
11. Install the 4th synchronizer cone(B).
12. Install the 4tr inner synchronizer ring(C).
13. Install the 4th gear sleeve(A) using press.
14. Install the 4th needle bearing(A).
15. Apply MT oil to the needle bearing.
16. Install the 4th gear(A).
17. Install the 5th sleeve(A) using press and special tool(09455-33200).
18. Install the 5th needle bearing(A).
19. Install the 5th gear(A).
20. Install the 5th inner synchronizer ring(A).
21. Install the 5th synchronizer cone(B).
22. Install the 5th outer synchronizer ring(C).
23. Install the 5th synchronizer hub(A) using the press and special tool(09455-33200).
NOTE:
- When installling hub, make sure the direction as shown in the picture.
- When pressing the hub, make sure that the fingers of the 5th synchronizer ring(double cone) are seated correctly in the grooves of the hub.
24. Install the synchronizer key(A).
25. Install the 5th synchronizer sleeve.
NOTE:
- Put down the 5th slope face of sleeve with the identification mark.
- Make sure that the groove of sleeve inside is seated correctly in the groove of synchronizer hub.
26. Install the spacer (A) and the snap ring (B).
27. Install the ball bearing(A) by press.
28. Install the snap ring.
29. Install the front input shaft ball bearing by press.
30. Install the snap ring(A).
