Input Shaft/Bearing

Special Tool(s)


Disassembly

CAUTION: The inner synchronizer ring and the synchronizer cone must be handled very carefully.

1. General note
^ The design and assembly procedure for the third gear single synchronizer are the same as for fourth gear. The following steps are for a double synchronizer. Refer to the table in Specifications if synchronizer parts have to be newly installed.
^ If there any new installation of bearings, shafts or the transaxle housings is necessary, the transaxle must be shimmed.

2. CAUTION: The taper roller bearing is damaged when it is pressed off using the separating tool and cannot be reused.





Press the taper roller bearing on the clutch side off the driveshaft using the separating tool.

3. CAUTION: The taper roller bearing is damaged when it is pressed off using the separating tool and cannot be reused.





Press the taper roller bearing on the transaxle side off the driveshaft using the separating tool.

4. NOTE: See step 5





Press off the fifth gear wheel with the taper roller bearing.
1. Slide the snap-ring up out of the annular groove until it sits below the taper roller bearing.
2. Press off the fifth gear wheel together with the snap-ring and taper roller beaning.

5. CAUTION: Parts can be damaged when it is pressed off using the separating tool or an equivalent tool.





Press off the fifth gear wheel with the taper roller bearing.
1. Slide the snap-ring up out of the annular groove until it sits below the taper roller bearing.
2. Press off the fifth gear wheel together with the snap-ring and taper roller bearing.





6. Remove the fourth gear wheel.
1. Remove the fourth gear wheel.
2. Remove the needle roller bearing.
3. Remove the synchronizer ring.





7. Remove the third/fourth gear synchronizer assembly.
1. Remove the snap-ring.
2. Pull off the synchronizer assembly.





8. Remove the third gear wheel.
1. Outer synchronizer ring
2. Synchronizer cone
3. Inner synchronizer ring
4. Gear wheel (third gear)
5. Needle roller bearing


Assembly

1. NOTE: Do not oil taper roller bearings which are to be used again. New taper roller bearings can be installed without any treatment.

Carefully clean and check all sliding parts and lubricate them with Automatic. Transmission Fluid before assembly.

2. CAUTION: Immerse the double synchronizer units in a bath of transaxle fluid prior to installation.





Press the taper roller bearing on at the clutch end.
^ Press the taper roller bearing on using a suitable length of tube.

3. NOTE: See step





Install the third gear wheel.
1. Needle roller bearing
2. Gear wheel (third gear)
3. Inner synchronizer ring
4. Synchronizer cone
5. Outer synchronizer ring

4. NOTE: Install the synchronizer hub with the large collar facing outwards and the annular groove facing the small collar.





Installation position of the synchronizer assembly.

5. NOTE: Install the synchronizer hub with the large collar facing outwards.





Install the complete third/fourth gear synchronizer assembly.
1. Synchronizer assembly.
2. Install a new snap-ring.





6. Install the fourth gear wheel.
1. Synchronizer ring.
2. Needle roller bearing.
3. Gear wheel (fourth gear)





7. Press on the fifth gear wheel.
^ Press the fifth gear wheel on using a suitable length of tube.
^ Install a new snap-ring.





8. Press the taper roller bearing on.
^ Press the taper roller bearing on using a suitable length of tube.