Operation CHARM: Car repair manuals for everyone.

Input Shaft

Input Shaft





Disassembly

CAUTION: The inner synchronizer ring and the synchronizer cone must be handled very carefully.

1. General note
- The design and assembly procedure for the third gear single synchronizer are the same as for fourth gear. The following steps are for a double synchronizer.
- If there any new installation of bearings, shafts or the transaxle housings is necessary, the transaxle must be shimmed.





2. CAUTION: The taper roller bearing is damaged when it is pressed off using the special tool and cannot be reused.

Using the special tool, press the taper roller bearing on the clutch side off the input shaft.





3. CAUTION: The taper roller bearing is damaged when it is pressed off using the special tool and cannot be reused.

Using the special tool, press the taper roller bearing on the transaxle side off the input shaft.





4. CAUTION: Components maybe damaged when pressed off using the special tool or an equivalent tool.

Using the special tool, press off the fifth gear wheel and the taper roller bearing.
1. Slide the snap-ring up out of the annular groove until it sits below the taper roller bearing.
2. Press off the fifth gear wheel with the snap ring and taper roller bearing.





5. Remove the fourth gear wheel.
1. Remove the fourth gear wheel.
2. Remove the needle roller bearing.
3. Remove the synchronizer ring.





6. Remove the third and fourth gear synchronizer assembly.
1. Remove the snap-ring.
2. Remove the synchronizer assembly.





7. NOTE: Take care when pulling the selector ring off the gear synchronizer hub. The detent balls are spring-loaded.

Disassemble the 3rd and 4th gear synchronizer.
1. Remove the selector ring.
2. Gear synchronizer hub
3. Compression spring
4. Blocker bar
5. Detent ball





8. Remove the third gear wheel.
1. Synchronizer ring
2. Synchronizer cone
3. Gear wheel (third gear)
4. Needle roller bearing

Assembly

1. NOTE: Do not oil taper roller bearings, which are to be used again. New taper roller bearings can be installed without any treatment.

Carefully clean and check all sliding parts and lubricate them with Manual transmission fluid before assembly.





2. CAUTION: Immerse the double synchronizer units in manual transaxle fluid prior to installation. Press the taper roller bearing on at the clutch end.

Using a suitable length tube, press the taper roller bearing on.





3. NOTE: Do not oil taper roller bearings, which are to be used again. New taper roller bearings can be installed without any treatment.

Install the third gear wheel.
1. Install the needle roller bearing
2. Install the gear wheel (third gear)
3. Install the synchronizer ring
4. Install the synchronizer ring





4. Assemble the third and fourth gear synchronizer.
1. Install the compression springs.
2. Install the synchronizer bar and detent balls by pressing against the spring pressure.
3. Install the selector ring the right way round and slide it on.





5. NOTE: Install the synchronizer hub with the large collar facing outwards and the annular groove facing the small collar.

Installation position of the synchronizer assembly.





6. NOTE: Install the synchronizer hub with the large collar facing outwards.

Install the complete third and fourth gear synchronizer assembly.
1. Synchronizer assembly.
2. Install a new snap-ring.





7. Install the fourth gear wheel.
1. Synchronizer ring.
2. Needle roller bearing.
3. Gear wheel (fourth gear)





8. Press on the fifth gear wheel. Using a suitable length or tube, press on the fifth gear wheel. Install a new snap-ring.





9. Press on the taper roller bearing. Using a suitable length of tube, press on the taper roller bearing.