7. Input Shaft Assemble

Input Shaft Assemble

Tools Required
* DT 46495 (DW09925-98221) Gear, Bearing Installer
* DT 46496 (DW09940-53111) Gear, Bearing Installer




1. Install the third gear/synchronizer ring (1).

Important: Coat all of the inner parts the gear, the bearing, and the oil seal with gear fluid.


2. Install the 3rd gear bearing (2).




3. Install the 3rd-4th synchronizer springs to the hub.

Important: Position the synchronizer springs as shown.


4. Install the third-fourth synchronizer key to the hub.
5. Install the 3rd-4th hub (2) to the sleeve (1).





Important: Position the longer flange of hub toward the third gear and match the key and the ring groove.


6. Insert the 3rd-4th hub assembly into the input shaft (2).
7. Install the 3rd-4th hub assembly using a hammer and the DT 46496 (1).





Important: Do not overpress when installing the gear, bearing and hub assembly. If overpressed, the gear teeth may be damaged.


8. When installing gear, bearing and hub assembly, install them slowly using DT 46496 and a hammer. If overpressed, the gear teeth may be damaged.




9. Install the 3rd-4th synchronizer circlip.

Important: Match the ring groove to the key of hub.


10. Install the 4th synchronizer ring and wave spring.




11. Install the input shaft 4th gear bearing (2) and the 4th gear (1).




12. Install the 5th gear spacer (2) using DT 46495 (1) and a hammer.
13. Install the 3rd-4th input shaft left side bearing using DT 46495 and a hammer.




14. Install the input shaft right side bearing to the input shaft using DT 46495 and a hammer (1).
15. Install the gear unit. Refer to Transmission Disassemble (2. Transmission Disassemble).