Input Shaft And Gears

INPUT SHAFT AND GEARS

Disassembly and Assembly


GENERAL PRECAUTIONS

- Do not reuse snap ring.
- Position input shaft on the vise with back plate and remove gears and snap rings.





- For installation and removal of snap ring, position snap ring pliers and flat pliers at both sides of snap ring. Stretch snap ring, and move it with flat pliers.
- Disassemble gear components putting matching marks on the parts that do not affect any functions.

DISASSEMBLY






1.Remove input shaft rear bearing bolt (1), using Tool (A).










2.Install the suitable tools (A) onto input shaft rear bearing (1), and remove input shaft rear bearing (1) from input shaft.





3.Remove washer (1), 6th input gear (2) and 5th-6th synchronizer assembly (3).
4.Remove needle bearing.





5.Remove snap ring (1), washer and 5th input gear (2).
6.Remove washer.





7.Remove snap ring (1), washer, 4th input gear (2) and 3rd-4th synchronizer assembly (3).





8.Remove snap ring (1), washer and 3rd input gear (2).





9.Remove input shaft front bearing (1) from input shaft using a suitable tool.

INSPECTION AFTER DISASSEMBLY

Input Shaft and Gears





Check items below. If necessary, replace them with new ones.
- Damage, peeling, dent, uneven wear, bending, and other nonstandard conditions of the shaft.
- Excessive wear, damage, peeling, and other non-standard conditions of the gears.
Synchronizer





Check items below. If necessary, replace them with new ones.
- Damage and excessive wear of contact surfaces of coupling sleeve, synchronizer hub and insert key.
- Coupling sleeve and synchronizer hub must move smoothly.





- If any crack, damage, or excessive wear is found on cam face of baulk ring or working face of insert, replace it.
Bearing





Check items below. If necessary, replace them with new ones.
- Damage and rough rotation of bearing

ASSEMBLY

Note the following. Assembly is in the reverse order of disassembly. Disassembly And Assembly.





- Press-fit the input shaft front bearing (1) onto the input shaft using a suitable tool (A).





- Press-fit the input shaft rear bearing (1) onto the input shaft using a suitable tool (A), and Tool (B).





CAUTION:
- Do not reuse snap ring.
- Make sure that snap ring is securely installed in the groove.





- Be careful with the orientation of 3rd-4th synchronizer hub.










- Be careful with the orientation of 5th-6th synchronizer hub.