Input Shaft: Service and Repair

Input shaft, disassembling and assembling

Note:
^ When installing new gears or input shaft.
^ If parts are exchanged which will affect the position of the ball bearings, the input shaft must be re-adjusted. Adjustments





1. Circlip
^ Identification
^ Installation position; see Fig. 11 item 1
^ Determining thickness; see adjusting input shaft, Adjustments
2. Ball bearing
3. Circlip
^ Identification
^ Installation position; see Fig. 11 item 2
^ Determining thickness; see adjusting input shaft.
4. Transmission housing
5. Needle bearing
^ Removing; see Fig. 1
^ Installation position; see Fig. 2
^ Pressing in; see Fig. 3
6. Input shaft
^ Adjusting
7. Needle bearing
^ For 3rd gear
8. 3rd gear
9. Spring
^ Install in 3rd gear; see Fig. 9
^ Application
10. 3rd gear synchronizer ring
^ Checking for wear Fig. 10
11. Circlip
^ Installation position; see Fig. 11 item 3
12. 3rd and 4th gear synchronizer hub
^ Shoulder faces 3rd gear
^ Pressing off; see Fig. 8
^ Pressing on; see Fig. 13
13. Circlip
^ Installation position; see Fig. 11 item 4
^ Thickness must be remeasured when replacing synchronizer hub Fig. 12
14. 3rd and 4th gear operating sleeve
^ Installation position; see Fig. 14
15. 4th gear synchronizer ring
^ Checking for wear; see Fig. 10
16. Spring
^ Insert in 4th gear; see Fig. 9
^ Application
17. 4th gear
18. Needle bearing
^ For 4th gear
19. 5th gear
^ Pressing off; see Fig. 7
^ Pressing on; see Fig. 15
20. Circlip
^ Installation position; see Fig. 11, item 5
^ Re-determine thickness when replacing 5th gear; see Fig. 12
21. Needle bearing
^ Always replace (damaged during removal)
^ Pulling out; see Fig. 4
^ Installation position; see Fig. 5
^ ^Driving In; see Fig. 6
22. Plastic sleeve
23. Transmission cover





Fig. 1 Driving-out needle bearing.





Fig. 2 Pressed-in depth for needle bearing
Dimension -a- from lower edge of straight-edge to upper edge of bearing: 39.5 mm (1.555 inch)





Fig. 3 Pressing needle roller bearing in





Fig. 4 Pulling out needle bearing
A- Internal extractor, e g. Kukko 21/4, 22 - 28 mm

Note: Destroy plastic sleeve before installing puller





Fig. 5 Installation position of needle bearing
Dimension a = 216 mm (8.50 inch)





Fig. 6 Driving in needle bearing





Fig. 7 Pressing off 5th gear
A - Separating device 22 - 115 mm, e.g. Kukko 17/2





Fig. 8 Pressing off 3rd and 4th gear synchronizer hub
- Press 3rd gear synchronizer ring (arrow) towards 3rd gear, then install separating device -A-.
A- Separating device 22 - 115 mm, e.g. Kukko 17/2





Fig. 9 Installing spring in gear
- Install spring in gear and hook angled end (arrow) into hole.





Fig. 10 Checking synchronizer ring for wear
- Press ring into operating sleeve and measure gap "a" with feeler gauge at positions -A-, -B- and -C-.
- Add measured values together and divide by 3.
^ Resulting average must not be less than 0.5 mm (0.020 inch).





Fig. 11 Position of circlips
^ Circlips -1- and -2- secure input shaft ball bearing; adjusting input shaft. Adjustments
^ Circlip -3- secures 3rd and 4th gear synchronizer hub. It is always 2 mm thick
Identification: color - brown
Part No.: N 902 945 01.
^ Circlip -4- secures 3rd and 4th gear synchronizer hub. The thickness is determined according to table.
Identification: color - blue
^ Circlip -5- secures 5th gear. The thickness is determined according to table.





Fig. 12 Determining thickness of Circlip
- Determine thickest Circlip which will just fit and install it.
^ Circlip 4-, for 3rd and 4th gear synchronizer hub.





The following circlips are available:
^ Circlip -5-, for 5th gear.





The following circlips are available:





Fig. 13 Pressing on 3rd and 4th gear synchronizer hub





Fig. 14 Installation position of operating sleeve
The chamfer (arrow -1-) faces 4th gear
The stepped side (arrow-2-) faces 3rd gear





Fig. 15 Pressing on 5th gear
The higher collar faces reverse gear