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.




5. REMOVAL OF 4TH SPEED GEAR
Remove the 4th speed gear together with spacer and inner race using the special tool as illustrated.
15. REMOVAL OF 3RD SPEED GEAR
Remove the 3rd speed gear together with 3rd-4th speed synchronizer assembly and bearing sleeve 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 tree 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 weakness, deformation and breakage.

SPEED GEARS




- 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

10. 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.

9. INSTALLATION OF 3RD-4TH SPEED SYNCHRONIZER ASSEMBLY




1. Install the synchronizer assembly with its hub end face having a small round depression in the oil groove facing the 3rd speed gear.

NOTE: The assembly may not be installed if set oppositely because it has been so designed that the end face of hub inside splines with a small round depression is easier to be inserted.

2. Press the 3rd-4th speed synchronizer assembly onto the input shaft using the special tools.

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.

7. INSTALLATION OF BEARING SLEEVE




Use the special tool as illustrated.

4. INSTALLATION OF SPACER




Some spacers have an identification marked on them. When using such spacers, make sure that the marked side faces the 4th speed gear. Spacers without identification mark may be installed in either direction.

3. INSTALLATION OF INNER RACE




Install the inner ring over the input shaft using the special tools.

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.)