Disassembly of Input Shaft Assembly

1. MEASURE THIRD AND FOURTH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the clearance.

Standard clearance:
3rd gear 0.10 - 0.25 mm (0.0039 - 0.0098 in.)
4th gear 0.20 - 0.45 mm (0.0079 - 0.0177 in.)

Maximum clearance:
3rd gear 0.30 mm (0.0118 in.)
4th gear 0.50 mm (0.0197 in.)




2. CHECK OIL CLEARANCE OF THIRD AND FOURTH GEAR
Using dial indicator, measure the oil clearance between the gear and shaft.

Standard clearance: 0.009 - 0.053 mm (0.0004 - 0.0021 in.)
Maximum clearance: 0.070 mm (0.0028 in.)

If the clearance exceeds the limit, replace the gear, needle roller bearing or shaft.




3. REMOVE SNAP RING
Using two screwdrivers and a hammer, tap out the snap ring.




4. REMOVE REAR BEARING, FOURTH GEAR, NEEDLE ROLLER BEARINGS, SPACER AND SYNCHRONIZER RING FROM INPUT SHAFT
a. Using SST and a press, press out the 4th gear and rear bearing.
SST 09950-00020
b. Remove the needle roller bearings, spacer and synchronizer ring.




5. REMOVE SNAP RING
Using snap ring pliers, remove the snap ring.




6. REMOVE NO.2 HUB SLEEVE ASSEMBLY, THIRD GEAR, SYNCHRONIZER RING AND NEEDLE ROLLER BEARINGS
Using SST and a press, remove No.2 hub sleeve, 3rd gear, synchronizer ring and needle roller bearings.
SST 09950-00020