Input Shaft Assembly
INPUT SHAFTCOMPONENTS:
REMOVAL
1. INSPECT 4TH GEAR THRUST CLEARANCE
a. Using a feeler gauge, measure the thrust clearance.
Standard clearance: 0.10 to 0.57 mm (0.0039 to 0.0224 inch)
If the clearance is out of specification, replace the No. 2 transmission clutch hub, 4th gear or input shaft rear radial ball bearing.
2. INSPECT 3RD GEAR THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 inch)
If the clearance is out of specification, replace the No. 2 transmission clutch hub, 3rd gear or input shaft.
3. INSPECT 4TH GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the radial clearance.
Standard clearance:
Standard clearance
If the clearance is out of specification, replace the 4th gear, needle roller bearing or input shaft.
4. INSPECT 3RD GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the gear radial clearance.
Standard clearance:
Standard clearance
If the clearance is out of specification, replace the 3rd gear, needle roller bearing or input shaft.
5. REMOVE 4TH GEAR
a. Hold the input shaft assembly in a vise with soft jaws.
b. Using 2 screwdrivers and a hammer, tap out the input shaft rear bearing shaft snap ring from the input shaft.
HINT: Cover with a shop rag to keep the snap ring from flying off.
c. Using SST and a press, press out the input shaft rear bearing and 4th gear.
SST 09950-00020
NOTICE: Do not overtighten the SST.
6. REMOVE 4TH GEAR NEEDLE ROLLER BEARING
a. Remove the needle roller bearing from the input shaft.
7. REMOVE 2ND SYNCHRONIZER OUTER RING
a. Remove the 2nd synchronizer outer ring (No. 4 synchronizer ring) from the No. 2 transmission clutch hub.
8. REMOVE 4TH GEAR BUSH
a. Remove the 4th gear bush from the No. 2 transmission clutch hub.
9. REMOVE 3RD GEAR
a. Using 2 screwdrivers and a hammer, remove the No. 2 clutch hub setting shaft snap ring from the input shaft.
HINT: Cover with a shop rag to keep the snap ring from flying off.
b. Using SST and a press, remove the No. 2 transmission clutch hub and 3rd gear from the input shaft.
SST 09950-00020
NOTICE: Do not overtighten the SST.
10. REMOVE 3RD GEAR NEEDLE ROLLER BEARING
a. Remove the needle roller bearing from the input shaft.
11. REMOVE NO. 3 SYNCHRONIZER RING
a. Remove the No. 3 synchronizer ring from the 3rd gear.
12. REMOVE NO. 2 TRANSMISSION HUB SLEEVE
a. Remove the No. 2 transmission hub sleeve, 3 No. 2 synchromesh shifting keys and 3 No. 2 synchromesh shifting key springs from the No. 2 transmission clutch hub.
HINT: Cover with a shop rag to keep the shifting key and shifting key spring from flying off.
13. REMOVE INPUT SHAFT FRONT BEARING
a. Using SST and a press, press out the input shaft front bearing (inner race) from the input shaft.
NOTICE: Do not overtighten the SST.
INSTALLATION
1. INSTALL FRONT INPUT SHAFT BEARING
a. Using SST and a press, press in the front bearing (inner race).
SST 09608-00071
2. INSTALL NO. 2 TRANSMISSION HUB SLEEVE
a. Coat the No. 2 transmission hub sleeve with gear oil, and install it to the No. 2 transmission clutch hub.
NOTICE: Set the No. 2 transmission clutch hub sleeve and the No. 2 transmission clutch hub in the correct orientation.
b. Using a screwdriver, install the 3 synchromesh key springs with the 3 synchromesh shifting keys to the No. 2 transmission clutch hub.
3. INSTALL 3RD GEAR NEEDLE ROLLER BEARING
a. Coat the 3rd gear bearing with gear oil, and install it to the input shaft.
4. INSTALL 3RD GEAR
a. Coat the 3rd gear with gear oil, and install it to the input shaft.
5. INSTALL NO. 3 SYNCHRONIZER RING
a. Coat the No. 3 synchronizer ring with gear oil, and install it to the 3rd gear.
6. INSTALL NO. 2 TRANSMISSION CLUTCH HUB
a. Using SST and a press, press in the No. 2 transmission clutch hub to the input shaft.
NOTICE:
^ Align the claw of the No. 2 clutch hub with the notch of the No. 3 synchronizer ring and install them.
^ Make sure that the 3rd gear can rotate.
b. Select a No. 2 clutch hub setting shaft snap ring so that the clearance between the No. 2 transmission clutch hub and the No. 2 clutch hub setting shaft snap ring will be within specification. Using a brass bar and hammer, install the No. 2 clutch hub setting shaft snap ring.
Standard clearance: 0.1 mm (0.004 inch) or less
Standard snap ring thickness:
Standard snap ring thickness
7. INSTALL 4TH GEAR BUSH
a. Coat the 4th gear bush with gear oil, and install it to the input shaft.
8. INSTALL 2ND SYNCHRONIZER OUTER RING
a. Coat the 2nd synchronizer outer ring (No. 4 synchronizer ring) with gear oil, and install it to the No. 2 transmission clutch hub.
NOTICE: Align the claw of the No. 2 clutch hub with the notch of the 2nd synchronizer outer ring (No. 4 synchronizer ring) and install it.
9. INSTALL 4TH GEAR NEEDLE ROLLER BEARING
a. Coat the needle roller bearing with gear oil, and install it to the input shaft.
10. INSTALL 4TH GEAR
a. Coat the 4th gear with gear oil, and install it to the input shaft.
11. INSTALL REAR INPUT SHAFT RADIAL BALL
a. Using SST and a press, press in the rear radial ball bearing to the input shaft.
SST 09608-06041
NOTICE:
^ Install the bearing with its groove for the snap ring facing upward.
^ Make sure that the 3rd gear rotates.
b. Select a rear bearing shaft snap ring so that the clearance between the rear radial ball bearing and the rear bearing shaft snap ring will be within specification. Using a brass bar and hammer, install the rear bearing shaft snap ring.
Standard clearance: 0.1 mm (0.004 inch) or less
Standard snap ring thickness:
Standard snap ring thickness
12. INSPECT 3RD GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the radial clearance.
Standard clearance:
Standard clearance
If the clearance is out of specification, replace the 3rd gear, needle roller bearing or input shaft.
13. INSPECT 4TH GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the radial clearance.
Standard clearance:
Standard clearance
If the clearance is out of specification, replace the 4th gear, needle roller bearing or input shaft.
14. INSPECT 3RD GEAR THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 inch)
If the clearance is out of specification, replace the No. 2 transmission clutch hub, 3rd gear or input shaft.
15. INSPECT 4TH GEAR THRUST CLEARANCE
a. Using a feeler gauge, measure the thrust clearance.
Standard clearance: 0.10 to 0.57 mm (0.0039 to 0.0224 inch)
If the clearance is out of specification, replace the No. 2 transmission clutch hub, 4th gear or input shaft rear radial ball bearing.
INSPECTION
1. INSPECT INPUT SHAFT
a. Using a V-block and dial indicator, measure the shaft for runout.
Maximum runout: 0.03 mm (0.0012 inch)
If the runout is greater than the maximum, replace the input shaft.
b. Using a micrometer, measure the outside diameter of the input shaft journal surface.
Standard outside diameter:
Standard outside diameter
Minimum outside diameter:
Minimum outside diameter
If the outside diameter is less than the minimum, replace the input shaft.
2. INSPECT 4TH GEAR
a. Using a cylinder gauge, measure the inside diameter of the 4th gear.
Standard Inside Diameter: 42.009 to 42.025 mm (1.6933 to 1.6939 inch)
Maximum Inside Diameter: 42.025 mm (1.6939 inch)
If the inside diameter is greater than the maximum, replace the 4th gear.
3. INSPECT 3RD GEAR
a. Using a cylinder gauge, measure the inside diameter.
Standard inside diameter: 43.009 to 43.025 mm (1.6933 to 1.6939 inch)
Maximum inside diameter: 43.025 mm (1.6939 inch)
If the inside diameter is greater than the maximum, replace the 3rd gear.
4. INSPECT 2ND SYNCHRONIZER OUTER RING
a. Coat the 4th gear cone with gear oil. Turn the 2nd synchronizer outer ring (synchronizer ring No. 4) in one direction while pushing it against the 4th gear cone. Check that the ring locks.
If the 2nd synchronizer outer ring does not lock, replace the ring or the 4th gear.
b. Using a feeler gauge, measure the clearance between the 2nd synchronizer outer ring (No. 4 synchronizer ring) back and 4th gear spline end.
Standard clearance: 0.75 to 1.65 mm (0.0295 to 0.0650 inch)
If the clearance is out of specification, replace the 2nd synchronizer outer ring.
5. INSPECT NO. 3 SYNCHRONIZER RING
a. Coat the 3rd gear cone with gear oil. Turn the No. 3 synchronizer ring in one direction while pushing it against the 3rd gear cone. Check that the ring locks.
If the No. 3 synchronizer ring does not lock, replace the ring or the 3rd gear.
b. Using a feeler gauge, measure the clearance between the No. 3 synchronizer ring back and 3rd gear spline end.
Standard clearance: 0.65 to 1.75 mm (0.0256 to 0.0689 inch)
If the clearance is out of specification, replace the No. 3 synchronizer ring.
6. INSPECT NO. 2 TRANSMISSION HUB SLEEVE
a. Inspect the sliding condition between the No. 2 transmission hub sleeve and No. 2 transmission clutch hub.
b. Inspect the tip of the spline gear on the No. 2
transmission hub sleeve for wear.
If any defects are found, replace the transmission hub sleeve or the transmission clutch hub.
c. Using vernier calipers, measure the width of the No. 2 transmission hub sleeve groove (A) and the thickness of the claw part on the No. 2 gear shift fork (B), and calculate the clearance.
Standard clearance: A - B = 0.11 to 0.69 mm
If the clearance is out of specification, replace the No. 2 transmission hub sleeve and No. 2 gear shift fork with new ones.