Input Shaft and Gears

DISASSEMBLY





1. Before disassembly, check 5th input gear end play.
Gear end play: Refer to Manual Transmission/Transaxle; Specifications.
^ 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.





4. Remove snap ring of input shaft front bearing and input gear 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.

Synchronizers





^ Check spline area of coupling sleeves, hubs and gears 40r wear or cracks.
^ Check baulk rings for cracks or deformation.
^ Check insert springs for wear or deformation.





^ Measure clearance between baulk ring and gear.
Clearance between baulk ring and gear: Refer to Manual Transmission/Transaxle; Specifications..

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 shifting insert.





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





5. Select correct snap ring of input shaft front bearing to minimize clearance of groove in input shaft and then install it.
Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 inch)
Snap rings of input shaft front bearing: Refer to Application and ID.
^ Be sure to replace 5th synchronizer hub with new one when it is removed.





6. Install 5th gear needle bearing, 5th input gear, 5th synchronizer and 5th stopper.
^ Input shaft must be vertical to press on synchronizer hub.
7. Measure gear end play as a final check. Refer to "DISASSEMBLY".





8. Select correct snap ring of 5th synchronizer hub to minimize clearance of groove in input shaft and install it.
Allowable clearance of groove: 0 - 0.1 mm (0 - 0.004 inch)
Snap rings of input shaft 5th synchronizer hub: Refer to Application and ID.