Intermediate Shaft

INTERMEDIATE SHAFT

DISASSEMBLY




1. Remove the snap ring.
2. Remove the ball bearing, 1st gear, bearing sleeve and needle roller bearing.

CAUTION: Do not reuse the bearing removed from the shaft.




3. Remove the 1st-2nd gear synchronizer assembly, 2nd gear and the needle roller bearing together, using the special tool (09432-24000).




4. Remove the ball bearing using the special tool (09433-21000).

CAUTION: Do not reuse the bearing removed from the shaft.

INSPECTION

INTERMEDIATE SHAFT




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

NEEDLE BEARING




1. Install the needle bearing on the shaft with the bearing sleeve and gear and 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 that are in contact with each speed 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 a rough surfaces, damage or wear.
3. Check the gear bore for damage or wear.

ASSEMBLY




1. Install the ball bearing over the intermediate shaft using the special tool (09432-33300).

CAUTION: When installing the bearing, push on the inner race only.

2. Install the 1st gear synchronizer ring noting its identification mark.




3. Combine the 1st-2nd gear synchronizer hub and sleeve.




4. 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 the synchronizer key.




5. 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 facing the same direction.




6. Install the needle roller bearing, 2nd gear, 1st-2nd gear synchronizer assembly over the intermediate 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 on the synchronizer ring.
2. After installation of the synchronizer assembly, check that 3rd gear rotates smoothly.




7. Install the needle roller bearing, 1st gear and bearing sleeve together using the special tool (09432-33300).




8. Install the ball bearing using the special tool (09432-33300).

CAUTION: When installing the bearing, push on the inner race only.

9. Install the snap ring.