Input Shaft: Service and Repair

INPUT SHAFT AND GEARS

DISASSEMBLY
1. Before disassembly, check 5th input gear end play. Gear end play: 0.18 - 0.31 mm (0.0071 - 0.0122 inch)
If not within specification, disassemble and check contact surface of gear, shaft and hub. Then check clearance of snap ring groove. Refer to Assembly.





2. Remove snap ring and 5th stopper.
3. Remove 5th synchronizer, 5th input gear and 5th gear needle bearing with Tool.





4. Remove snap ring of input shaft front bearing and spacer.
5. Pull out input shaft front bearing.
6. Remove bearing retainer.

INSPECTION





Gear And Shaft
- Check shaft for cracks, wear or bending.
- Check gears for excessive wear, chips or cracks.





Synchronizer
- Check spline portion of coupling sleeves, hubs and nears for wear or cracks.
- Check baulk rings for cracks or deformation.
- Check shifting inserts for wear or deformation.





- Measure clearance between baulk ring and gear. Clearance between baulk ring and gear:
Standard: 1.0 - 1.35 mm (0.0394 - 0.0531 inch)
Wear limit: 0.7 mm (0.028 inch)





Bearing
- Make sure bearings roll freely and are free from noise, cracks, pitting or wear.








ASSEMBLY
1. Assemble 5th synchronizer. Be careful not to hook front and rear ends of spread spring to the same insert.





2. Install bearing retainer.
3. Press on input shaft front bearing.
4. Install spacer.








5. Select and install snap ring that gives the proper clearance of groove in input shaft.
Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 inch)
Refer to the illustration for snap ring and input shaft front bearing information.





6. Install 5th gear needle bearing, 5th input gear, 5th synchronizer and 5th stopper with Tool.
7. Measure gear end play as the final check.








8. Select and install snap ring that gives the proper clearance of groove in input shaft.
Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 inch)
Refer to the illustration for snap ring and 5th synchronizer information.