Input Shaft

Input Shaft

Special Tool(s):

Material:

Input Shaft (Part 1):

Input Shaft (Part 2):

Disassembly

CAUTION: The inner synchronizer ring and the synchronizer cone must be handled very carefully.

NOTE: If there any new installation of bearings, shafts or the transaxle housings is necessary, the transaxle must be shimmed.





1. CAUTION: The roller bearing is damaged when it is pressed off using the special tool and cannot be reused.

Position the input shaft on the press with the input shaft splines facing upward. Using the special tool, remove and discard the roller bearing.





2. CAUTION: The roller bearing is damaged when it is pressed off using the special tool and cannot be reused.

Reposition the input shaft with 5th gear end facing upward. Using a suitable press and the special tool, remove the roller bearing.
3. Using a suitable press and the special tool, remove the snap ring and 5th gear.





4. Remove the 4th gear.
1 Remove the 4th gear.
2 Remove the 4th gear needle bearing.
3 Remove the synchronizer ring.
^ Check all components for wear or damage. Install new components as necessary.





5. Remove the 3rd/4th gear synchronizer assembly.
1 Remove and discard the snap ring.
2 Remove the 3rd/4th gear synchronizer assembly.
^ Check the synchronizer for wear or damage. Install a new synchronizer as necessary.
^ Inspect the gear for wear or damage. Install a new gear, as necessary.





6. Disassemble the 3rd/4th gear synchronizer assembly. Remove the selector ring from the synchronizer hub. Remove the compression springs, the blocker bars and the detent balls.
^ Take care when pulling the selector ring off the gear synchronizer hub. The detent balls are spring-loaded.
7. Inspect the 3rd/4th synchronizer.
^ Check for worn, nicked or broken teeth.
^ Install a new synchronizer as necessary.
^ Check keys for wear or distortion. Install a new synchronizer as necessary.
^ Check springs for distortion. Install a new synchronizer as necessary.





8. Remove the synchronizer ring, 3rd gear and the 3rd needle gear bearing.
^ Inspect the synchronizer ring, 3rd gear and the needle bearing for wear or damage. Install new components as necessary.

Assembly

1. NOTE: Using a suitable press, install the gear wheels.

Carefully clean and check all sliding parts and lubricate them with clean manual transmission fluid before assembly.





2. Using a length of suitable tube, install the clutch housing roller bearing.





3. Install the 3rd gear needle bearing, 3rd gear, gear wheel and the synchronizer ring.





4. Assemble the 3rd/4th gear synchronizer.
1 Install the compression springs.
2 Install the synchronizer bar and detent balls by pressing against the spring pressure.
3 Install the selector ring the right way round and slide it on.








5. NOTE: Install the synchronizer hub with the large collar facing outward and the annular groove facing the small collar.

NOTE: Install a new snap ring.

Install the 3rd/4th gear synchronizer assembly.
1 Install the synchronizer assembly.
2 Install a new snap ring.





6. Install the 4th gear.
1 Install the synchronizer ring.
2 Install the 4th gear needle bearing.
3 Install the 4th gear.





7. Using a suitable press, install 5th gear. Install a new snap ring.





8. Using a length of suitable tube, install the transaxle housing roller bearing.