Input Shaft and Gears
DISASSEMBLY
1. Before disassembly, measure the end plays of 3rd and 4th input gears with a suitable tool.
Gear end play: Refer to "Gear End Play", under Specifications; Mechanical.
- If end play is not within specification, disassemble and check the parts.
2. Remove oil channel from input shaft rear bearing.
3. Press out input shaft rear bearing using Tool.
4. Remove C-ring holder.
5. Remove 5th gear rear C-ring.
6. Remove 5th input gear from input shaft using Tool.
7. Remove 5th gear front C-ring.
8. Remove 4th input gear, baulk ring, 4th gear needle bearing, and 4th gear C-ring from input shaft.
9. Press out both 3rd & 4th synchronizer hub assembly and 3rd input gear from input shaft using Tool.
10. Remove 3rd gear needle bearing.
11. Press out input shaft front bearing from input shaft using Tool.
INSPECTION
Gear and Shaft
- Check shaft for cracks, wear or bending.
- Check gears for excessive wear, chips or cracks.
Synchronizers
- Check spline area of coupling sleeves, hubs and gears for wear or cracks.
- Check baulk rings for cracks or deformation.
- Check insert springs for wear or deformation.
- If any crack, damage, or excessive wear is found on cam face of baulk ring or working face of insert, replace it.
1 of 2
2 of 2
- Measure the movement (play, dimension "L") of 3rd & 4th coupling sleeve with the end fixed and the other end lifted as shown in the figure. If the movement exceeds specification, replace the sleeve.
- Measure clearance between baulk ring and gear.
Clearance between baulk ring and gear: Refer to "Clearance Between Baulk Ring and Gear", under Specifications; Mechanical.
Bearing
- Make sure bearings roll freely and are free from noise, cracks, pitting or wear.
ASSEMBLY
1. Press on input shaft front bearing using Tool.
2. Install 3rd gear needle, 3rd input gear and 3rd gear baulk ring bearing to input shaft.
3. Install spread spring, shifting insert, and 3rd & 4th synchronizer hub onto 3rd & 4th coupling sleeve.
- Pay attention to the shape of spread spring and shifting insert for correct assembly.
- Do not install spread spring hook onto the same shifting insert.
CAUTION: Do not reuse 3rd & 4th synchronizer hub.
- Install synchronizer hub with its three grooves facing the front side (3rd input gear side).
- Install 3rd & 4th coupling sleeve with its chamfered surface facing the 4th input gear side.
4. Position bearing replacer to the front side of input shaft front bearing.
- Align grooves of shifting insert and 3rd gear baulk ring. Then, press it onto 3rd & 4th synchronizer hub assembly using a drift.
5. Install 4th gear C-ring onto input shaft using Tool.
6. Measure the end play of 3rd & 4th synchronizer hub with a suitable tool, and check if it is within allowable specification below.
End play: 0 - 0.06 mm (0 - 0.0024 inch)
7. If not within specification, adjust the end play by changing thickness of 4th (input) gear C-ring.
4th (input) gear C-ring: Refer to "Available C-rings", under Application and ID.
8. Install 4th gear needle bearing, 4th gear baulk ring, and 5th gear front C-ring.
9. Install 4th input gear using Tool.
10. Position 5th input gear as shown in the figure, and install it on input shaft.
11. Install 5th input gear.
CAUTION: Do not reuse 5th input gear.
12. Install 5th gear rear C-ring onto input shaft using Tool.
13. Measure the end play of 5th input gear with a suitable tool, and check if it is within the allowable specification below.
End play: 0 - 0.06 mm (0 - 0.0024 inch)
14. If not within specification, adjust the end play by changing thickness of the 5th (input gear) rear C-ring.
5th (input gear) rear C-ring: Refer to "Available C-rings", under Application and ID.
15. Install C-ring holder onto 5th gear rear C-ring using Tool.
CAUTION: Do not reuse C-ring holder.
16. Install input shaft rear bearing using Tool.
CAUTION: Install input shaft rear bearing with its brown surface facing the input gear side.
17. Install oil channel onto input shaft.
18. Measure gear end play as a final check.