Input Shaft: Disassembly

Fig 1: Input Shaft

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Before disassembly of the input shaft (1), it is necessary to check the synchronizer stop ring gap. Use a feeler gauge to measure the gaps between the stop rings (2,5 and 8) and the speed gears. The correct gaps are listed below: See Fig 1.

1. 1st - 0.522-2.208 mm (0.021-0.087 in)
2. 2nd - 0.522-2.208 mm (0.021-0.087 in)
3. 3rd - 0.73-1.53 mm (0.029-0.060 in)
4. 4th - 0.77-1.57 mm (0.030-0.062 in).
5. 5th - 0.73-1.53 mm (0.029-0.060 in)
6. Reverse Brake-0.505-1.74 mm (0.020-0.068 in.)

The reverse brake measurement is taken between the stop ring and case.

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.

Fig 2: 5th Gear Synchronizer Snap Ring Removal/Installation

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1. Install bearing splitter (3) behind 5th speed gear. Remove snap ring (4) at 5th synchronizer hub on input shaft (2). See Fig 2.
   Fig 3: Remove Synchronizer Using Shop Press

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   1 - PRESS RAM

   2 - INPUT SHAFT

   3 - BEARING SPLITTER

   4 - SYNCHRONIZER ASSEMBLY

2. Remove synchronize (4) and gear using shop press (1). See Fig 3.
   Fig 4: Caged Needle Bearing Removal/Installation

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   1 - INPUT SHAFT

   2 - CAGED NEEDLE BEARING

3. Remove caged needle bearing (2). See Fig 4.
   Fig 5: Split Thrust Washer Ring

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   1 - SPLIT THRUST WASHER RING

   2 - INPUT SHAFT

4. Remove 4-5 gears split thrust washer ring (1). See Fig 5.
   Fig 6: Split Thrust Washer Removal/Installation

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   1 - INPUT SHAFT

   2 - SPLIT THRUST WASHER

5. Remove split thrust washer (2). See Fig 6.
   Fig 7: Split Thrust Washer Separation Pin

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   1 - SEPARATION PIN

   2 - INPUT SHAFT

   3 - PLIERS

6. Remove split thrust washer separation pin (1). See Fig 7.
   Fig 8: 4th Gear Removal

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   1 - INPUT SHAFT

   2 - 4TH GEAR

7. Remove 4th gear (2). See Fig 8.
   Fig 9: Caged Needle Bearing Removal

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   1 - INPUT SHAFT

   2 - CAGED NEEDLE BEARING

8. Remove 4th gear caged needle bearing (2). See Fig 9. Check the caged needle bearing (2) for a broken retention spring.
   Fig 10: 3-4 Synchronizer Hub Snap Ring

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   1 - SNAP RING PLIERS

   2 - SYNCHRO SNAP RING

   3 - SYNCHRONIZER ASSEMBLY

9. Remove blocking ring. Remove 3-4 synchronizer hub retaining snap ring (3). See Fig 10.
   Fig 11: 3rd Gear Removal

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   1 - PRESS RAM

   2 - INPUT SHAFT

   3 - 3RD GEAR

   4 - SYNCHRONIZER ASSEMBLY

10. Install input shaft in shop press (1). See Fig 11. Using bearing splitter, remove 3-4 synchronizer and 3rd gear (3).
    Fig 12: 3rd Gear Caged Needle Bearing

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    1 - INPUT SHAFT

    2 - 3RD GEAR CAGED NEEDLE BEARING

11. Remove 3rd gear caged needle bearing (2). See Fig 12. Inspect 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.