Input Shaft Disassembly and Reassembly
Input Shaft Disassembly and ReassemblyDisassembly
1. Remove input shaft right bearing (2) from input shaft (1) using bearing puller (3) and hydraulic press.
2. Drive out 5th gear spacer (2), left bearing (3) and 4th gear (4) all at once using puller (5) and hydraulic 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 snap ring pliers (2), remove circlip (1).
NOTE: For smooth removal of circlip, it is recommended to correct tool tips to be flat.
5. Drive out high speed synchronizer sleeve & hub assembly (2) together with 3rd gear (3) by using puller (4) and hydraulic press.
CAUTION: To avoid gear tooth from being damaged, support it at flat side of bearing puller.
6. Take out 3rd gear needle bearing from input shaft.
7. Disassemble synchronizer sleeve & hub assembly.
Reassembly
1. Clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary.
2. Check clearance "a" between synchronizer ring (2) and gear (1), key slot width "b" in synchronizer ring and each chamfered tooth of gear and synchronizer ring and replace with new one, if necessary. Also, check gear tooth.
Clearance "a" between synchronizer ring and gear
Standard: 1.0 - 1.4 mm (0.040 - 0.055 in.)
Service limit: 0.5 mm (0.020 in.)
Key slot width "b"
Standard: 10.0 - 10.2 mm (0.394 - 0.401 in.)
Limit: 10.45 mm (0.411 in.)
3. To ensure lubrication of input shaft (1), air blow oil holes (2) and make sure that they are free from any obstruction.
4. Fit high speed synchronizer sleeve (4) to hub (3), insert 3 keys (2) in it and then set springs (1) as shown in figure.
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 are the smaller than those of low speed one.
Synchronizer key installation position A = B
5. Drive in right bearing (1) to input shaft (2) using special tool and hydraulic press.
Special Tool (A):09913-80113
6. Install 3rd gear needle bearing (4), apply oil to it, then install 3rd gear (1) and synchronizer ring (2).
7. Drive in high speed sleeve & hub assembly (3) by using special tool and hydraulic press.
NOTE:
^ While press-fitting sleeve & hub, make sure that synchronizer ring key slots are aligned with keys (5) in sleeve & hub assembly.
^ Check free rotation of 3rd gear after press-fitting sleeve & hub assembly.
^ Synchronizer rings for 3rd and 4th are identical.
Special Tool
(B):09913-84510
[A]: 3rd gear side
8. Install circlip (1) and confirm that circlip is installed in groove securely. Install needle bearing (2) of apply oil to it and then install synchronizer ring (3) and 4th gear (4).
9. Press-fit left bearing (2) by using special tool and hydraulic press.
Special Tool (A):09913-80113
10. Using the same special tool at step 9), drive in 5th gear spacer (1).
CAUTION: To prevent 5th gear spacer (1) from being distorted because of excessive compression, do not press-fit it with left bearing (2) at once.
