Input Shaft Assembly
DISASSEMBLY1. Remove input shaft R bearing spacer and circlip.
2. Drive out 5th gear spacer, L bearing and 4th gear all at once by using puller and press.
CAUTION:
- To avoid gear tooth from being damaged, support it at flat side of bearing puller.
- Stop press work in the middle way and take out 5th gear bush to prevent it from being compressed and then continue to remove bearing with gear.
3. Take out 4th gear needle bearing and high speed synchronizer ring.
4. Using special tool, remove circlip
NOTE: For smooth removal of circlip, it is recommended to correct tool tips to be flat.
Special Tool
(A): 09900-06107
5. Drive out high speed synchronizer sleeve & hub assembly together with 3rd gear by using puller and press.
CAUTION: Make sure to use flat side of puller to avoid causing damage to 3rd gear tooth.
6. Take out 3rd gear needle bearing from shaft.
7. Disassemble synchronizer sleeve & hub assembly.
INSPECTION AND REASSEMBLY
1. Clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary.
2. If synchronizer parts need to be repaired, check clearance "a" between ring and gear, each chamfered tooth of gear, ring and sleeve, then determine parts replacement.
Clearance "a": Standard 1.0 - 1.4 mm (0.039 - 0.055 inch)
Service limit 0.5 mm (0.019 inch)
3. To ensure lubrication, air blow oil holes and make sure that they are free from any obstruction.
4. Fit high speed synchronizer sleeve to hub, insert 3 keys in it and then set springs as illustrated.
NOTE:
- No specific direction is assigned to high speed synchronizer sleeve or each key but it is assigned as assembly.
- Size of high speed synchronizer sleeve, hub, keys and springs is between those of low speed and 5th speed ones.
5. Drive in R bearing spacer by using special tool and hammer.
Special Tools
(A): 09913-80112
6. Install circlip to input shaft.
7. Press-fit L bearing by using special tool and hammer.
Special Tool
(A): 09913-80112
8. Using the same special tool, drive in 5th gear spacer.
CAUTION: To prevent 5th gear spacer from being distorted because of excessive compression, do not press-fit it with L bearing at once.