Intermediate Shaft

INTERMEDIATE SHAFT

Components





Disassembly





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





2. Remove the taper roller bearing, first speed gear and bearing sleeve, and needle roller bearing using the special tool (09432-33100).

CAUTION:
1) Do not reuse the bearing removed from the shaft.
2) Replace the inner and outer races of the tapered roller bearing as a set..





3. Remove the first-second speed synchronizer assembly and second speed gear, needle roller bearing together using the special tool (09432-33100).





4. Remove the taper roller bearing using the special tool (09432-33200).

CAUTION:
1) Do not reuse the bearing removed from the shaft.
2) Replace the inner and outer races of the tapered roller bearing as a set.

Inspection

- Intermediate Shaft





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

Clearance "A", Limit: 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 or breakage.

- Speed Gears





1. Check the bevel gear and clutch gear teeth for damage and wear.

Reassembly





1. Install the taper roller bearing over the intermediate shaft using the special tool (09432-33300).

CAUTION: When installing the bearing, push on the inner race only.

2. Install the first synchronizer ring noting its identification mark.





3. Combine the first-second speed synchronizer hub and sleeve.





4. The synchronizer sleeve has teeth missing at six positions. Assemble the hub to the sleeve so that the center tooth between the two missing teeth touches the synchronizer key.





5. 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 the same direction.





6. Install the needle roller bearing, second gear, first-second speed synchronizer assembly over the intermediate shaft using the special tool (09432-33300).

CAUTION:
1) When installing the synchronizer assembly, make sure that three synchronizer keys are seated correctly in their respective synchronizer ring grooves.
2) After installing of the synchronizer assembly, check that 3rd speed gear rotates smoothly.





7. Install the needle roller bearing, first speed gear, bearing sleeve together using the special tool (09432-33300) as illustrated.





8. Install the taper roller bearing using the special tool (09432-33300)

CAUTION: When installing the bearing, push on the inner race only.

9. Install the snap ring.