Input Shaft

Input Shaft













Disassembly

1. Prior to disassembly of the input shaft, measure and record the end play for the 3rd, 4th and 5th gears. Refer to the following chart for standard values:









2. Remove the oil channel.

3. Using the Bearing Puller and a suitable press, remove the input shaft rear bearing.





4. NOTE: The snap ring is not reusable.

Remove and discard the snap ring.





5. Using the Bearing Puller and a suitable press, remove the input shaft spacer and the 5th gear stopper together.





6. Using the Bearing Puller and a suitable press, remove the 5th gear synchronizer assembly, the 5th gear synchronizer ring and the 5th input gear together.
- Discard the 5th gear synchronizer ring and assembly.





7. Remove the 5th gear needle bearing.

8. Using the Bearing Puller and a suitable press, remove the 5th gear bushing, thrust washer, 4th input gear, 4th gear needle bearing, 4th gear bushing, 4th gear synchronizer ring, 3rd and 4th gear synchronizer assembly, 3rd gear synchronizer ring and 3rd input gear together.
- Discard the 5th gear bushing.

- Discard the 3rd and 4th gear synchronizer assembly.





9. Remove the 3rd gear needle bearing.

10. Using the Bearing Puller and a suitable press, remove the input shaft front bearing.





11. Inspect all input shaft parts for damage, peeling, dents, uneven wear or bending. Install new parts as necessary.





12. Inspect the synchronizer rings for damage. Install new parts as necessary.





13. NOTE: Limit value: 0.7 mm (0.027 in).

Press the synchronizer ring against the cone and measure the clearance between the synchronizer ring and gear cone. Install a new synchronizer ring if the measurement is not within specification. Refer to the following chart for correct synchronizer ring clearance:









Assembly

1. Using the Input Bearing Installer and the Spindle/Axle Shaft Installer with the Bearing Puller, press on the input shaft front bearing.





2. Install the 3rd gear needle bearing.

3. Install the 3rd input gear.

4. Install the 3rd gear synchronizer ring.

5. NOTE: Make sure the synchronizer side with 3 notches is facing the 3rd input gear and the synchronizer side with 4 notches is facing the 4th gear.

Install a new 3rd and 4th gear synchronizer assembly.





6. Install the 4th gear synchronizer ring.

7. Using the Spindle/Axle Shaft Installer with the Bearing Puller, press on the 4th gear bushing.





8. Install the 4th gear needle bearing.

9. Install the 4th input gear.

10. NOTE: Only one thrust washer can be selected.

Select the correct thickness thrust washer.

- Measure the distance as shown.

- If the measurement is not within 154.7-154.8 mm (6.09-6.094 in), select the correct thickness of shim from the following chart:









11. Using the Spindle/Axle Shaft Installer with the Bearing Puller, press on the thrust washer.





12. Using the Spindle/Axle Shaft Installer with the Bearing Puller, press on a new 5th gear bushing.





13. Install the 5th gear needle bearing.

14. Install the 5th input gear.

15. Install a new 5th gear synchronizer ring.

16. NOTE: Make sure the synchronizer side with the 3 notches is facing the 4th input gear.

Install a new 5th gear synchronizer assembly.





17. Using the Spindle/Axle Shaft Installer with the Bearing Puller, press on the 5th gear stopper and input shaft bearing spacer together.





18. Install the input shaft spacer.

19. Install new snap ring. Measure the gap between the snap ring groove and the snap ring. The end play should be between 0-0.1 mm (0-0.003 in). Refer to the following chart for the correct snap ring thickness:









20. Using the Input Bearing Installer and the Spindle/Axle Shaft Installer with the Bearing Puller, press on the input shaft rear bearing.





21. Install the oil channel.