Input Shaft

Tools Required
- 87-92-152-Input Shaft Puller
- 87-91-642-Basic Puller
- 87-91-121-Input Shaft Puller Ring
- 87-90-636-Pinion Fixture

DISASSEMBLY





1. Mount input shaft in a vise with soft jaws.
2. Remove bearing retaining ring and discard.





NOTICE: The input shaft bearing cannot be reused after removal. It must be replaced.

NOTICE: Loosen tool X7-92-152 until tool sits flush on 4th drive gear before tightening tool onto bearing.

3. Remove input shaft bearing using tools 87-92-152 and 87-91-642.





4. Remove 4th drive gear, 4th gear blocking ring, and 4th gear bearing.





5. Move 3rd/4th gear synchronizer sleeve down (towards third gear) far enough to remove synchronizer detent inserts with a small screwdriver.





IMPORTANT: Note the orientation of 3rd/4th gear synchronizer sleeve. It needs to be installed in same orientation.

6. Remove 3rd/4th gear synchronizer sleeve.





7. Remove 3rd/4th gear synchronizer insert pins and springs.
8. Remove 3rd/4th gear synchronizer hub retaining ring
and washer. Remove 3rd/4th synchronizer hub.





9. Remove 3rd gear blocking ring, 3rd drive gear, and 3rd gear bearing assembly.





10. Press off input shaft bearing (next to 1st drive gear) using tools 87-91-121 and 87-90-636.
11. Check condition of gears and synchronizers.

Tools Required
- 87-91-261-Output Shaft Remover

ASSEMBLY





IMPORTANT: Lubricate all rotating parts and bearings with manual transaxle fluid (P/N 21018899) during assembly.

1. Install 3rd gear bearing assembly, 3rd drive gear, and 3rd gear blocking ring.





IMPORTANT: Install hub with synchronizer hub washer groove facing up.

2. Install 3rd/4th gear synchronizer hub. Align gaps in synchronizer hub with blocking ring lugs.
3. Install 3rd/4th gear synchronizer hub washer and retaining ring. The square edge on retaining ring faces up (towards 4th gear).
4. Measure clearance between 2nd and 3rd drive gears.
Clearance:
Standard: 0.05 mm - 0.40 mm (0.002 inch - 0.015 inch)





5. Install 3rd/4th gear synchronizer springs and pins.





IMPORTANT: The tall teeth on the 3rd/4th synchronizer sleeve must align with deep tooth gaps in the synchronizer hub.

6. Install 3rd/4th synchronizer sleeve onto synchronizer hub.





IMPORTANT: Do not move synchronizer sleeve after installing detent inserts. The inserts will not stay in position if the sleeve is moved. Only move sleeve after installing 4th drive gear.

7. Move 3rd/4th gear synchronizer sleeve down (towards third gear) far enough to install synchronizer detent inserts. Use a small screwdriver to depress pins and springs, and install detent inserts.





IMPORTANT: The 4th gear blocking ring lugs must align with the gaps in the synchronizer hub.

8. Install 4th gear blocking ring to synchronizer hub.
9. Install 4th gear bearing assembly and 4th drive gear.
10. Hold down 4th gear and move synchronizer sleeve up and down to check for proper operation.





11. Press on new input shaft bearing (next to 4th drive gear) using sleeve 87-91-261. Support shaft under 2nd drive gear.

NOTICE: When installing new bearing retaining ring, open the ring only as far as necessary to fit ring over shaft. Opening ring too far will damage it.

12. Install a new bearing retaining ring. Make sure chamfered edge on ring is facing up (away from bearing).





13. Measure clearance between 4th drive gear and input shaft bearing.
Clearance:
Standard: 0.05 mm - 0.40 mm (0.002 inch - 0.015 inch)





14. Press on new input shaft bearing (next to 1st drive gear) using sleeve from tool 87-91-261.