Input Shaft Assembly

Components:

INPUT SHAFT DiSASSEMBLY







1. MEASURE THIRD AND FOURTH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.

Standard clearance:
3rd gear 0.10 - 045 mm (0.0039 - 0.0177 in.)
4th gear 0.10 - 0.55 mm (0.0039 - 0.0217 in.)

Maximum clearance:
3rd gear 0.50 mm (0.0197 in.)
4th gear 0.60 mm (0.0236 in.)




2. CHECK OIL CLEARANCE OF THIRD AND FORTH GEAR
Using dial indicator, measure the oil clearance between the gear and shaft.

Standard clearance:
3rd gear 0.009 - 0.053 mm (0.0004 - 0.0021 in.)
4th gear 0.009 - 0.051 mm (0.0004 - 0.0020 in.)

Maximum clearance:
3rd and 4th gear 0.070 mm (0.0028 in.)

If clearance exceeds the limit, replace the gear, needle roller bearing or shaft.




3. REMOVE SNAP RING
Using two screwdriver and a hammer, tap out the snap ring.




4. REMOVE RADIAL BALL BEARING AND FOURTH GEAR
Using SST and a press, remove the radial bearing.
SST 09950-00020
5. REMOVE NEEDLE ROLLER BEARINGS, SPACER AND SYNCHRONIZER RING




6. REMOVE SNAP RING
Using two screwdrivers and a hammer, tap out the snap ring.




7. REMOVE NO.2 CLUTCH HUB ASSEMBLY, SYNCHRONIZER RING AND THIRD GEAR
Using a press, remove No.2 hub sleeve, 3rd gear, synchronizer ring and needle roller bearings.
8. REMOVE NEEDLE ROLLER BEARING

INPUT SHAFT COMPONENT PARTS INSPECTION




1. INSPECT SYNCHRONIZER RING FOR THIRD GEAR
a. Check for wear damage.
b. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone and check that the ring is locked.
If the braking effect is insufficient, replace the synchronizer ring.




c. Measure the clearance between the synchronizer ring back and gear spline end.

Minimum clearance: 0.7 mm (0.028 in.)

If the clearance is less than the limit, replace the synchronizer ring.




2. INSPECT SYNCHRONIZER RING FOR FOURTH GEAR
a. Check for wear or damage.
b. Check the braking effect of the synchronizer ring. A Turn the synchronizer ring in one direction while pushing it to the gear cone and check that the ring is locked.
If the braking effect is insufficient, lightly rub the synchronizer ring and gear cone by applying a small amount of fine lapping compound.

NOTE:
- Wash off completely the fine lapping compound after rubbing.
- Check again the braking effect of the synchronizer ring.




c. Measure the clearance between the synchronizer ring back and spline end.

Minimum clearance: 0.6 mm (0.024 in.)

If the clearance is less than the limit, replace the synchronizer ring and gear cone by applying a small amount of fine lapping compound.

NOTE: Wash off completely, the fine lapping compound after rubbing.




3. MEASURE CLEARANCE OF NO.2 SHIFT FORK AND HUB SLEEVE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.

Maximum clearance: 1.0 mm (0.039 in.)

If the clearance exceeds the limit, replace the shift fork or hub sleeve.




4. INSPECT INPUT SHAFT
a. Check the input shaft for wear or damage.
b. Using a micrometer, measure the outer diameter of the input shaft journal surface.

Maximum clearance:
Part A 27.950 mm (1.1004 in.)
Part B and C 35.950 mm (1.4154 in.)




c. Using a dial indicator, check the shaft runout.

Maximum clearance: 0.05 mm (0.0020 in.)

INPUT SHAFT ASSEMBLY





HINT: Coat all of the sliding and rotating surface with gear oil before assembly.

1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE
a. Install the three springs and shifting keys to the clutch hub.
b. Install the hub sleeve to the clutch hub.

HINT: Direct identification groove of the hub sleeve to front of the transmission.




2. INSTALL NEEDLE ROLLER BEARING, THIRD GEAR, SYNCHRONIZER RINGS AND NO.2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT
a. Apply MP grease to the needle roller bearing.
b. Assembly the needle roller bearings into the 3rd gear.
c. Place the synchronizer rings on the gear and align the ring slots with the shifting keys.




d. Using SST and a press, install the 3rd gear and No.2 hub sleeve.
SST 09506-35010







3. INSTALL SNAP RING
a. Select a snap ring that will allow minimum axial play.




b. Using a screwdriver and hammer, tap in the snap ring.




4. MEASURE THIRD GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 3rd gear thrust clearance.

Standard clearance: 0.10 - 0.45 mm (0.0039 - 0.0177 in.)




5. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE ROLLER BEARINGS, FOURTH GEAR AND RADIAL BALL BEARING
a. Install the spacer.
b. Apply MP grease to the needle roller bearings.
c. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
d. Install the 4th gear.
e. Using SST and a press, install the radial ball bearing.
SST 09506-35010







6. INSTALL SNAP RING
a. Select a snap ring that will allow minimum axial play.




b. Using a screwdriver and hammer, tap in the snap ring.




7. MEASURE FOURTH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 4th gear thrust clearance.

Maximum clearance: 0.10 - 0.55 mm (0.0039 - 0.0217 in.)