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Input Shaft: Service and Repair





DISASSEMBLY AND REASSEMBLY

SERVICE POINTS OF DISASSEMBLY

2. REMOVAL OF BALL BEARING




Remove the front bearing using the special tool as illustrated.

3. REMOVAL OF BEARING SLEEVE




Remove the bearing sleeve using the special tool as illustrated.

5. REMOVAL OF BALL BEARING
Remove the ball bearing together using the special tool as illustrated.

20. REMOVAL OF 3RD SPEED GEAR




Remove the bearing sleeve, 3rd-4th speed synchronizer assembly and 3rd speed gear together using the special tool as illustrated.

INSPECTION
INPUT SHAFT




- Check the outer surface of the input shaft where the needle bearing is mounted for damage, abnormal wear and seizure [portion A]
- Check the splines for damage and wear.

NEEDLE BEARING




- Combine the needle bearing with the shaft or bearing sleeve and gear and check that it rotates smoothly without abnormal noise or play.
- Check the needle bearing cage for deformation.

SYNCHRONIZER RING




- Check the clutch gear teeth for damage and breakage.
- Check the internal surface for damage, wear and broken threads.




- Force the synchronizer ring toward the clutch gear and check clearance "A". Replace if it is out of specification

Limit: 0.5 mm (0.02 in.)

SYNCHRONIZER SLEEVE AND HUB




- Combine the synchronizer sleeve and hub and check that they slide smoothly.
- Check that the sleeve is free from damage at its inside front and rear ends.
- Check for wear of the hub end surfaces (in contact with each speed gear).

CAUTION: When replacing, replace the synchronizer hub and sleeve as a set.

SYNCHRONIZER KEY AND SPRING




- Check for wear of the synchronizer key center protrusion.
- Check the spring for deterioration, deformation and breakage.

SPEED GEARS




- Check the bevel gear and clutch gear teeth for damage and wear.
- Check the synchronizer cone for rough surface, damage and wear.
- Check the gear bore and front and rear ends for damage and wear.

SERVICE POINTS OF REASSEMBLY

15. INSTALLATION OF SYNCHRONIZER SPRING




Install the synchronizer spring so that its protrusion fits into the groove in the synchronizer key.
Make sure that the protrusions in the front and rear springs are not in the groove of the same key.

14. INSTALLATION OF 3RD-4TH SPEED SYNCHRONIZER SPRING




1. The synchronizer assembly should be installed so that the place where there is a small indentation in the oil channel of the hub end surface is at the 3rd gear side.

NOTE: If installation were in the reverse way, it might happen that press-in could not be done.

The reason for this is because the design is so that the end of the hub inner-diameter spline that has the small round indentation can be pressed in easily.

2. Press the 3rd-4th speed synchronizer assembly over the input shaft using the special tool as illustrated.

CAUTION: When installing the synchronizer assembly, make sure that three synchronizer keys are seated correctly in respective grooves of the synchronizer ring.

3. Check the 3rd speed gear rotates smoothly.

12. INSTALLATION OF BEARING SLEEVE




Use the special tool as illustrated.

9. INSTALLATION OF SUB GEAR/8. CONE SPRING/7.SNAP RING




Install the sub gear and cone spring to 4th gear, and then install the snap ring.

NOTE: Be sure that the cone spring is installed so that it is facing in the correct direction.

6. INSTALLATION OF SPACER




Some spacers bear an identification mark. For such spacers, install so that the surface that is not marked faces toward the 4th gear side. Spacers without an identification mark can be installed in either direction.

5. INSTALLATION OF BALL BEARING




Install the ball bearing over the input shaft using the special tool.

4. INSTALLATION OF SNAP RING




Install a snap ring so that the input shaft rear bearing end play will be the standard value.

Standard value: 0.01 - 0.09 mm (0.0004 - 0.004 in.)

3. INSTALLATION OF BEARING SLEEVE




Using special tool, attach the bearing sleeve on the input shaft.

CAUTION: When press-fitting the sleeve on the input shaft, verify that the flange of the sleeve fits closely on the bearing.

2. INSTALLATION OF BALL BEARING




Install the ball bearing over the input shaft using the special tool.

1. INSTALLATION OF SNAP RING




Snap rings are available in three different thickness. Select the thickest one that fits in the snap ring groove.

CAUTION: Do not cause damage to the input shaft oil seal contacting portion.

Standard value: 0.01 - 0.12 mm (0.0004 - 0.005 in.)
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