Input Shaft

INPUT SHAFT

DISASSEMBLY




1. Remove the snap ring using the special tool (09432-21201).




2. Remove the front bearing using the special tool (09432-21300).




3. Remove the inner ring, spacer, 4th gear, needle bearing, bearing sleeve, synchronizer rings, 3rd and 4th gear synchronizer hub and sleeve and 3rd gear all together using the special tool (09432-33200)

INSPECTION

INPUT SHAFT




1. Check the outer surface of the input shaft where the needle bearing is mounted for damage or abnormal wear [portion (A)].
2. Check the splines for damage or wear.

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 : 0.5 mm (0.02 in.)

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).

CAUTION: Replace the synchronizer hub and sleeve as a set.

SYNCHRONIZER KEY AND SPRING




1. Check for wear of the synchronizer key center protrusion.
2. Check the spring for weakness, distortion or damage.

GEARS




1. Check the bevel gear and clutch gear teeth for damage or wear.
2. Check the gear cone for rough surfaces, damage or wear.
3. Check the gear bore for damage or wear.

ASSEMBLY




1. Install the synchronizer hub and sleeve so that they are positioned as shown in the figure.




2. The synchronizer sleeve has teeth missing at six places. Assemble the hub to the sleeve so that the center tooth between the two missing teeth will touch synchronizer key.




3. Install the synchronizer spring so that the stepped portions will rest on the synchronizer keys.

CAUTION: When installing the synchronizer springs. make sure they are not lacing the same direction.




4. Install the needle roller bearing and 3rd gear on the input shaft.
5. Install the 3rd-4th gear synchronizer assembly on the input shaft using the special tool (09432-33300).

CAUTION:
1. When installing the synchronizer assembly, make sure that the three synchronizer keys are seated correctly in their respective grooves of the synchronizer ring.
2. After installing the synchronizer assembly, check that 3rd gear rotates smoothly.




6. Install the needle roller bearing sleeve using the special tool (09432-33300).
7. Install the synchronizer ring, needle roller bearing, 4th gear, the spacer and the inner ring using the special tool (09432-33300).




8. Install the front bearing using the special tool (09432-33300).
9. Install the snap ring.

CAUTION: Be careful not to damage the input shaft oil seal surface on the input shaft.