Input Shaft And Gears

INPUT SHAFT AND GEARS

Disassembly and Assembly


GENERAL PRECAUTIONS

- Do not reuse snap ring.
- Secure input shaft in a vise with backplate, and then remove gears and snap rings.





- For installation and removal of snap ring, set snap ring pliers and flat pliers at both sides of snap ring. While expanding snap ring with snap ring pliers, move snap ring with flat pliers.
- Disassemble gear components putting direction marks on the parts that do not affect any functions.

DISASSEMBLY






1.Remove input shaft rear bearing bolt (1) using Tool (A).

CAUTION:
Do not reuse input shaft rear bearing bolt.
Tool number(A): KV-32300QAM (-)





2.Remove input shaft rear bearing (1) according to the following procedures.
a.Set a suitable puller to input shaft rear bearing.
b.Remove input shaft rear bearing using a suitable drift (A).





3.Remove spacer (1), 6th input gear (2), needle bearing, 6th baulk ring, and 5th-6th synchronizer hub assembly (3).
4.Remove insert keys and 5th-6th coupling sleeve from 5th-6th synchronizer hub.





5.Remove snap ring (1) using suitable tool.

CAUTION:
Do not reuse snap ring.
6.Remove spacer, 5th baulk ring, 5th input gear (2), and spacer.





7.Remove snap ring (1) using suitable tool.

CAUTION:
Do not reuse snap ring.
8.Remove spacer, 4th input gear (2), 4th baulk ring, and 3rd-4th synchronizer hub assembly (3).
9.Remove insert keys and 3rd-4th coupling sleeve from 3rd-4th synchronizer hub.





10.Remove snap ring (1).

CAUTION:
Do not reuse snap ring.
11.Remove spacer, 3rd baulk ring, 3rd input gear (2).





12.Set a suitable puller to input shaft front bearing (1), and then remove input shaft front bearing.

INSPECTION AFTER DISASSEMBLY

Input shaft and gear
Check the following items and replace if necessary.





- Damage, peeling, bend, uneven wear, and distortion of shaft.
- Excessive wear, damage, and peeling of gear.
Synchronizer
- Synchronizer hub and coupling sleeve
Check the following items and replace if necessary.





- Breakage, damage, and unusual wear on contact surface of coupling sleeve, synchronizer hub, and insert key.
- Coupling sleeve and synchronizer hub move smoothly.
- Baulk ring





Check contact surface of baulk ring cam and insert key for excessive wear, uneven wear, bend, and damage. Replace if necessary.
Bearing





Check bearing for damage and rough rotation. Replace if necessary.

ASSEMBLY

Note the following procedures, and assemble in the reverse order of disassembly.

CAUTION:
- Replace transaxle assembly when replacing input shaft.
- Do not reuse snap ring.
- Check that snap ring is securely installed in a groove.
- Replace 3rd-4th coupling sleeve and 3rd-4th synchronizer hub as a set.
- Replace 5th-6th coupling sleeve and 5th-6th synchronizer hub as a set.





- Be careful to install 3rd-4th synchronizer hub according to the specified direction.










- Be careful to install 5th-6th synchronizer hub according to the specified direction.










- Install input shaft front bearing (1) using a suitable drift (A).





- Install input shaft rear bearing (1) using a suitable drift (A) and the
Tool (B).
Tool number(B): ST-36720030 (-)
- Apply gear oil to 3rd baulk ring, 4th baulk ring, 5th baulk ring, and
6th baulk ring.





- Install input shaft rear bearing bolt (1) according to the following procedures.

CAUTION:
- Do not reuse input shaft rear bearing bolt.
- Follow the procedures. Otherwise it may cause a transaxle malfunction.
1.Secure the Tool (A) in a vise, and then set input shaft assembly.
Tool number(A): KV-32300QAM (-)
2.Install input shaft rear bearing bolt, and then tighten it to the specified torque of the 1st step. Disassembly And Assembly.
3.Loosen input shaft rear bearing bolt by a half turn.
4.Tighten input shaft rear bearing bolt to the specified torque of the 2nd step. Disassembly And Assembly.