Input Shaft

INPUT SHAFT

TOOLS REQUIRED
- 87-90-636 Pinion Fixture
- 87-91-121 Input Shaft Puller Ring
- 87-91-261 Output Shaft Remover
- 87-91 -642 Basic Puller
- 87-92- 152 Input Shaft Puller

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 S7-92-152 until tool sits flush on 4th drive gear before tightening tool onto bearing.





3. Remove input shaft bearing using tools Input Shaft Puller 87-92-152 and Basic Puller 87-91-642.





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

CAUTION: THE SYNCHRONIZER DETENT INSERTS MAY BE FORCED OUT BY SPRING PRESSURE AND COULD INJURE SOMEONE. TO HELP AVOID INJURY, ALWAYS COVER THE SYNCHRONIZER HUB DETENT OPENINGS DURING DISASSEMBLY.





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 Input Shaft Puller Ring 87-91-121 and Pinion Fixture 87-90-636.





When a manual transaxle with a serial number before T02075 is repaired for a 3rd/4th gear synchronizer concern, it must be determined whether the synchronizer components are of the 1st design or the 2nd design.
The following illustrations show the 1st (left half of illustration) and 2nd (right half of illustration) design of the 3rd/4th gear synchronizer components.

IMPORTANT: All transaxles built prior to the T02075 serial number will be of the 1st design unless they have been previously repaired for this condition. All service parts are of the 2nd design.

11. If the 3rd/4th synchronizer sleeve removed from the transaxle has the profile of the sleeve shown on the left, then it is a 1st design. The 2nd design synchronizer sleeve will have a symmetrical profile.





12. If the 3rd/4th gear blocking ring removed from the transaxle looks like the blocking ring shown on the left half of illustration, then it is of the 1st design.

If any of these 3rd/4th shift components are a 1st design and need to be replaced, then both blocking rings, the sleeve, and the shift fork must be replaced with the 2nd design parts as a unit. If the blocking rings, sleeve, and shift fork have already been replaced with the 2nd design components, then only replace parts as needed.
13. Check condition of gears and synchronizers.

ASSEMBLY

IMPORTANT: Lubricate all rotating parts and bearings with manual transaxle lubricant (PAL 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 - 0.40 mm (0.002 - 0.015 inch)





5. Install 3rd/4lh 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.





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 Output Shaft Remover 87-91-26. 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: 0.02 - 0.40 mm (0.002 - 0.015 inch)





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