Input Shaft

INPUT SHAFT

Components





Disassembly





1. Remove the snap ring using the special tool (09432-21201).





2. Remove the front bearing using the special tool (09432-21300).





3. Remove the bearing sleeve using the special tool (09455-21000).
4. Remove the snap ring.





5. Remove the rear bearing using the special tool (09432-21300).
6. Remove the corn spring and sub gear.





7. Remove the fourth speed, needle roller bearing, synchronizer ring, and third-fourth speed synchronizer sleeve.
8. Remove the needle roller bearing sleeve, third-fourth synchronizer hub, synchronizer ring, third speed gear and needle roller bearing using the special tool (09432-21300).

Inspection

Input Shaft





1. Check the outer surface of the input shaft where the needle bearing is mounted for damage or abnormal wear (portion [A])
2. Check the splines for damage or wear.

Needle Bearing





1. Combine the needle bearing with the shaft or bearing sleeve and gear and check that it rotates smoothly without abnormal noise or play.
2. Check the needle bearing cage for deformation.

Synchronizer Ring





1. Check the clutch gear teeth for damage and breakage.
2. Check the internal surface for damage, wear and broken threads.





3. Force the synchronizer ring toward the clutch gear and check clearance "A". Replace if it is out of specification.

Limit:
Clearance "A" 0.5 mm (0.02 inch)

Synchronizer Sleeve and Hub





1. Combine the synchronizer sleeve and hub and check that they slide smoothly.
2. Check that the sleeve is free from damage at its inside front and rear ends.
3. Check for wear of the hub end surfaces (in contact with each speed gear).

CAUTION: Replace the synchronizer hub and sleeve as a set.

Synchronizer Key and Spring





1. Check for wear of the synchronizer key center protrusion.
2. Check the spring for weakness, deformation and breakage.

Speed Gears





1. Check the bevel gear and clutch gear teeth for damage and wear.
2. Check the synchronizer cone for rough surface, damage and wear.
3. Check the gear bore and front and rear ends for damage and wear.

Reassembly





1. Install the synchronizer hub and sleeve so that they are positioned as shown in the figure.





2. The synchronizer sleeve has teeth missing at six portions. Assemble the hub to the sleeve in such a way that the center tooth between the two missing teeth will touch the synchronizer key.





3. Install the synchronizer spring so that its protrusion fits into the groove in the synchronizer key.

CAUTION:
When installing the synchronizer springs, make sure that the front and rear ones are not faced in same direction.





4. Install the needle roller bearing and third speed gear to the input shaft.
5. Install the third-fourth speed synchronizer assembly over the input shaft using the special tool (09432-33300).

CAUTION:
1) When installing the synchronizer assembly, make sure that three synchronizer keys are seated correctly in respective grooves of the synchronizer ring.
2) After installing the synchronizer assembly, check that the third speed gear rotates smoothly.





6. Install the needle roller bearing sleeve using the special tool (09432-33300).
7. Install the synchronizer ring, needle roller bearing, fourth gear and spacer.
8. Install the corn spring and sub gear.





9. Install the rear bearing using the special tool (09432-33300).
10. Install the snap ring.





11. Install the rear bearing sleeve using the special tool (09432-33300)





12. Install the front bearing using the special tool (09432-33300).
13. Install the snap ring.