Disassembly

C50 MANUAL TRANSAXLE: INPUT SHAFT: DISASSEMBLY

1. INSPECT 4TH GEAR THRUST CLEARANCE





(a) Using a feeler gauge, measure the 4th gear thrust clearance.

Standard clearance:

0.1 to 0.55 mm (0.0039 to 0.0217 in.)

Maximum clearance:

0.55 mm (0.0217 in.)

If the clearance exceeds the maximum, 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 gauge, measure the 3rd gear thrust clearance.

Standard clearance:

0.1 to 0.35 mm (0.0039 to 0.0138 in.)

Maximum clearance:

0.35 mm (0.0138 in.)

If the clearance exceeds the maximum, 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 4th gear radial clearance between the gear and shaft.

Standard clearance:

0.009 to 0.050 mm (0.0004 to 0.0020 in.)

Maximum clearance:

0.050 mm (0.0020 in.)

If the clearance exceeds the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft.

4. INSPECT 3RD GEAR RADIAL CLEARANCE





(a) Using a dial gauge, measure the 3rd gear radial clearance between the gear and shaft.

Standard clearance:

JTEKT made bearing
0.015 to 0.058 mm (0.0006 to 0.0023 in.)

NSK made bearing
0.015 to 0.056 mm (0.0006 to 0.0022 in.)

Maximum clearance:

JTEKT made
0.058 mm (0.0023 in.)

NSK made
0.056 mm (0.0022 in.)

If the clearance exceeds the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft.

5. REMOVE 4TH GEAR





(a) Using 2 screwdrivers and a hammer, remove the input shaft rear bearing shaft snap ring from the input shaft.

HINT
Use a piece of cloth to keep the snap ring from flying off.

(b) Using SST and a press, remove the input shaft rear radial ball bearing and 4th gear from the input shaft.





SST : 09950-00020

HINT
* Do not tighten SST excessively.
* Support the input shaft assembly by hand to prevent it from dropping off.

6. REMOVE 4TH GEAR NEEDLE ROLLER BEARING





(a) Remove the 4th gear needle roller bearing and 4th gear bearing spacer from the input shaft.

7. REMOVE 4TH GEAR SYNCHRONIZER RING





(a) Remove the No. 2 synchronizer ring from the No. 2 transmission clutch hub.

8. REMOVE 3RD GEAR





(a) Using 2 screwdrivers and a hammer, remove the clutch hub No. 2 setting shaft snap ring from the input shaft.

HINT
Use a piece of cloth to keep the snap ring from flying off.

(b) Using SST and a press, remove the No. 2 transmission clutch hub and the 3rd gear from the input shaft.





SST : 09950-00020

NOTICE:
* Do not tighten SST excessively.
* Support the input shaft by hand to prevent it from dropping off.

9. REMOVE 3RD GEAR SYNCHRONIZER RING





(a) Remove the No. 2 synchronizer ring from the 3rd gear.

10. REMOVE 3RD GEAR NEEDLE ROLLER BEARING





(a) Remove the 3rd gear needle roller bearing from the input shaft.

11. REMOVE NO. 2 TRANSMISSION HUB SLEEVE





(a) Remove the No. 2 transmission hub sleeve, the 3 shifting keys and 3 shifting key springs from the No. 2 transmission clutch hub.

NOTICE:
Use a piece of cloth to keep the shifting key and shifting key spring from flying off.