Input Shaft And Gears
INPUT SHAFT AND GEARS
Disassembly and Assembly
DISASSEMBLY
1. Before disassembling, measure end play for 3rd, 4th, 5th, and
6th input gears.
End play standard value : Refer to Gear End Play.
2. Remove oil channel.
3. Press out input shaft rear bearing using Tool and a puller.
4. Remove snap ring.
Tool number : ST33052000 ( - )
5. Press out 6th input gear, 6th needle bearing, 6th input gear bushing, 5th-6th synchronizer hub assembly, and 5th input gear using Tool (A) and a puller (B).
Tool number A: ST33052000 ( - )
6. Remove 5th needle bearing.
7. Press out 5th input gear bushing, thrust washer, 4th input gear, 4th needle bearing, 4th input gear bushing, 3rd-4th synchronizer hub assembly, and 3rd input gear using Tool and a puller.
Tool number : ST33052000 ( - )
8. Remove 3rd needle bearing.
9. Press out input shaft front bearing using a puller.
INSPECTION AFTER DISASSEMBLY
Input Shaft and Gears
Check items below. If necessary, replace them with new ones.
- Damage, peeling, dent, uneven wear, bending, etc. of shaft
- Excessive wear, damage, peeling, etc. of gears
Synchronizer
Check items below. If necessary, replace them with new ones.
- Damage and excessive wear of contact surfaces of coupling sleeve, synchronizer hub and shifting insert
- Coupling sleeve and synchronizer hub must move smoothly.
- If any crack, damage, or excessive wear is found on cam face of baulk ring or working face of insert, replace it.
BAULK RING CLEARANCE
- Single-cone synchronizer (4th, 5th, and 6th)
Push baulk ring on the cone and measure the clearance between baulk ring and cone. If measurement is below limit, replace it with a new one.
- Double-cone synchronizer (3rd)
Check the clearance between outer baulk ring, synchronizer cone, and inner baulk ring as follows.
CAUTION:
The clearances (A) and (B) are controlled with outer baulk ring, synchronizer cone, and inner baulk ring as a set.
Replace them as a set if the clearances are outside the limit value.
1. Measure the clearance (A) at 2 points or more diagonally opposite using a dial indicator and Tool. And then calculate mean value.
2. Measure the clearance (B) at 2 points or more diagonally opposite using a feeler gauge. And then calculate mean value.
Bearing
Check items below. If necessary, replace them with new ones.
- Damage and rough rotation of bearing
ASSEMBLY
1. Install 3rd needle bearing to input shaft.
2. Install 3rd input gear, 3rd inner baulk ring, 3rd synchronizer cone, and 3rd outer baulk ring to input shaft.
CAUTION:
Replace 3rd inner baulk ring, 3rd synchronizer cone, and 3rd outer baulk ring as a set.
3. Install 3rd-4th spread springs, 3rd-4th shifting inserts, and 3rd-4th synchronizer hub onto 3rd-4th coupling sleeve.
CAUTION:
- Be careful with orientation of 3rd-4th synchronizer hub.
- Never reuse 3rd-4th synchronizer hub and 3rd-4th coupling sleeve.
- Replace 3rd-4th synchronizer hub and 3rd-4th coupling sleeve as a set.
- Be careful with orientation of 3rd-4th coupling sleeve.
- Be sure not to hook center projection of 2 spread springs on same shifting insert.
4. Press in 3rd-4th synchronizer hub assembly using Tool
Tool number : KV40105710 ( - )
CAUTION:
Align grooves of 3rd-4th shifting insert and 3rd outer baulk ring.
5. Press in 4th input gear bushing using Tool.
Tool number : KV40105710 ( - )
6. Install 4th baulk ring.
7. Install 4th needle bearing and 4th input gear to input shaft.
8. Select thrust washer so that dimension "C2" satisfies the standard value below. Then install thrust washer onto input shaft. Available Thrust Washer.
Standard value for dimension "C2" : Refer to Available Thrust Washer.
CAUTION:
Only one thrust washer can be selected.
9. Press in 5th input gear bushing using Tool.
Tool number : KV40105710 ( - )
CAUTION:
Never reuse 5th input gear bushing.
10. Install 5th needle bearing and 5th input gear to input shaft.
11. Install 5th baulk ring.
12. Install 5th-6th synchronizer hub, 5th-6th spread springs, and 5th-6th shifting inserts onto 5th-6th coupling sleeve.
CAUTION:
- Be careful with orientation of 5th-6th synchronizer hub.
- Never reuse 5th-6th synchronizer hub and 5th-6th coupling sleeve.
- Replace 5th-6th synchronizer hub and 5th-6th coupling sleeve as a set.
- Be careful with orientation of 5th-6th coupling sleeve.
- Be sure not to hook center projection of 2 spread springs on same shifting insert.
13. Press in 5th-6th synchronizer hub assembly using Tool.
Tool number : KV40105710 ( - )
CAUTION:
Align grooves of 5th-6th shifting insert and 5th baulk ring.
14. Install 6th needle bearing, 6th input gear, 6th baulk ring onto 6th input gear bushing and then press in 6th input gear bushing onto input shaft using Tool.
Tool number : ST33200000 (J-26082 )
15. Install snap ring onto input shaft and make sure that end play
(gap between snap ring and groove) of 6th input gear bushing satisfies the standard value.
End play standard value :Refer to Available Snap Rings.
- If measurement is outside the standard range, select snap ring. Available Snap Rings.
CAUTION:
Never reuse snap ring.
16. Press in input shaft rear bearing using Tool.
Tool number : ST30901000 (J-26010-01)
CAUTION:
Install input shaft rear bearing with its brown surface facing the 6th input gear side.
17. Press in input shaft front bearing Tools (A), (B).
18. Install oil channel onto input shaft.
19. Check end play of 3rd, 4th, 5th, and 6th input gears.
End play standard value : Refer to Gear End Play.