Input Shaft: Service and Repair

DISASSEMBLY





NOTE: Before disassembly of the input shaft, it is necessary to check the synchronizer stop ring gap. Use a feeler gauge to measure the gaps between the stop rings and the speed gears. The correct gaps are listed below:
1st: 1.04-1.72 mm (.0409-.0677 inch)
2nd: 0.94-1.72 mm (.0370-.0677 inch)
3rd: 1.37-1.93 mm (.0539-.0760 inch)
4th: 1.41-1.97 mm (.0555-.0776 inch)
5th: 1.37-1.93 mm (.0539-.0760 inch)
If a stop ring gap does not fall within the specifications it must be inspected for wear and replaced. If the 1st or 2nd synchronizer stop ring is worn beyond specifications, the complete output shaft assembly must be replaced. The input shaft incorporates the 3rd, 4th, and 5th speed gears and synchronizers on the assembly.





1. Install MD998801 or equivalent behind 5th speed gear. Remove snap ring at 5th synchronizer hub on input shaft.





2. Remove synchronizer and gear using shop press.





3. Remove caged needle bearing.





4. Remove 4-5 gears split thrust washer ring.





5. Remove split thrust washer.





6. Remove split thrust washer separation pin.





7. Remove 4th gear.





8. Remove 4th gear caged needle bearing. Check the caged needle bearing for a broken retention spring.





9. Remove blocking ring. Remove 3/4 synchronizer hub retaining snap ring.





10. Install input shaft in shop press. Using MD998801 to remove 3/4 synchronizer and 3rd gear.





11. Remove 3rd gear caged needle bearing. Check the caged needle bearing for a broken retention spring.
12. Inspect the input shaft for worn or damaged bearing races or chipped gear teeth. Replace as necessary.

ASSEMBLY

NOTE: The snap rings that are used on the input shaft are available in select fit sizes. Use the thickness snap ring that will fit in each snap ring groove.

1. Place input shaft into shop press.





2. Install 3rd gear caged needle bearing on input shaft.





3. Install 3rd gear and 3/4 synchronizer onto input shaft. Install MD998812, MD998813, MD998821 or equivalents over input shaft and press on synchronizer hub and 3rd gear. The synchronizer hub has the letter "U" stamped on the top face of the hub.
This designates that the hub must be installed with the "U" facing upward.





4. Install 3/4 synchronizer snap ring into slot on input shaft.





5. Install blocking ring into 3/4 synchronizer. Install 4th gear caged needle bearing.





6. Install 4th gear onto input shaft.





7. Install 4/5 split thrust washer separation pin.





8. Install split thrust washer onto input shaft.





9. Install split thrust washer retaining ring.





10. Install 5th gear caged needle bearing.





11. Using MD998812, MD998821 or equivalents, install 5th speed gear and synchronizer. The 5th gear synchronizer hub has the letter "S" stamped on the top face of the hub. This designates that hub must be installed with the "S" facing upward.





12. Install 5th gear synchronizer snap ring.