Input Shaft
INPUT SHAFTCOMPONENTS:
DISASSEMBLY
1. INSPECT 4TH GEAR THRUST CLEARANCE
2. INSPECT 3RD GEAR THRUST CLEARANCE
3. INSPECT 4TH GEAR RADIAL CLEARANCE
4. INSPECT 3RD GEAR RADIAL CLEARANCE
5. REMOVE 4TH GEAR
(a) Using 2 screwdrivers and a hammer, tap out the snap ring.
HINT: Use a shop rag or piece of cloth to keep the snap ring from flying.
(b) Using SST and a press, remove the input shaft rear radial ball bearing and 4th gear from the input shaft.
SST 09950-00020
NOTICE:
^ Do not tighten SST excessively.
^ Support the input shaft assembly by hand so that it will not be dropped off.
6. REMOVE 4TH GEAR NEEDLE ROLLER BEARING
(a) Remove the 4th gear needle roller bearing and 4th gear bearing spacer from the input shaft.
7. REMOVE 4TH GEAR SYNCHRONIZER RING
(a) Remove the 4th gear synchronizer ring from the transmission clutch hub No. 2.
8. REMOVE 3RD GEAR
(a) Using 2 screwdrivers and a hammer, tap out the snap ring.
HINT: Use a shop rag or piece of cloth to keep the snap ring from flying.
(b) Using SST and a press, remove the transmission clutch hub No. 2 and 3rd gear from the input shaft.
SST 09950-00020
NOTICE:
^ Do not tighten SST excessively.
^ Support the input shaft by hand so that it will not be dropped off.
9. REMOVE 3RD GEAR SYNCHRONIZER RING
(a) Remove the 3rd gear synchronizer ring from the 3rd gear.
10. REMOVE 3RD GEAR NEEDLE ROLLER BEARING
(a) Remove the 3rd gear needle roller bearing from the input shaft.
11. REMOVE TRANSMISSION HUB SLEEVE NO. 2
(a) Remove the transmission hub sleeve No. 2, 3 shifting key No. 2 and 3 shifting key spring No. 2 from the transmission clutch hub No. 2.
HINT: Using a shop rag or piece of cloth to prevent the shifting key and shifting key spring from being scattered.
12. INSPECT INPUT SHAFT
13. INSPECT 4TH GEAR
14. INSPECT 3RD GEAR
15. INSPECT 4TH GEAR SYNCHRONIZER RING
16. INSPECT 3RD GEAR SYNCHRONIZER RING
17. INSPECT TRANSMISSION HUB SLEEVE NO. 2
INSPECTION
1. INSPECT 4TH GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the 4th gear thrust clearance.
4th gear thrust clearance:
2. INSPECT 3RD GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 3rd gear thrust clearance.
3rd gear thrust clearance:
3. INSPECT 4TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 4th gear radial clearance.
4th gear radial clearance:
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
4. INSPECT 3RD GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 3rd gear radial clearance.
3rd gear radial clearance:
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
5. INSPECT INPUT SHAFT
(a) Using a dial indicator, check the shaft runout.
Maximum runout: 0.015 mm (0.0006 in.)
If the runout exceeds the maximum, replace the input shaft.
(b) Using a micrometer, measure the outer diameter of the input shaft journal surface.
Input shaft outer diameter:
If the outer diameter is below the minimum, replace the input shaft.
6. INSPECT 4TH GEAR
(a) Using a cylinder gauge, measure the inside diameter of the 4th gear.
Standard inside diameter: 34.015 to 34.031 mm (1.3392 to 1.3398 in.)
Maximum inside diameter: 34.031 mm (1.3398 in.)
If the inside diameter exceeds the maximum, replace the 4th gear.
7. INSPECT 3RD GEAR
(a) Using a cylinder gauge, measure the inside diameter of the 3rd gear.
Standard inside diameter: 36.015 to 36.031 mm (1.4179 to 1.4185 in.)
Maximum inside diameter: 36.031 mm (1.4185 in.)
If the inside diameter exceeds the maximum, replace the 3rd gear.
8. INSPECT 4TH GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Coat the 4th gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 4th gear cone. Check that the ring locks. If the synchronizer outer ring does not lock, replace the ring or the 4th gear.
(c) Using a feeler gauge, measure the clearance between the 4th gear synchronizer ring back and 4th gear spline end.
Minimum clearance: 0.65 mm (0.0256 in.)
If the clearance below than the minimum, replace the 4th gear synchronizer ring.
9. INSPECT 3RD GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Coat the 3rd gear cone with gear oil. Turn the synchronizer ring in one direction while pushing it against the 3rd gear cone. Check that the ring locks. If the synchronizer outer ring does not locks, replace the ring or the 3rd gear.
(c) Using a feeler gauge, measure the clearance between 3rd gear synchronizer ring back and 3rd gear spline end.
Minimum clearance: 0.75 mm (0.0295 in.)
If the clearance below than the minimum, replace the 3rd gear synchronizer ring.
10. INSPECT TRANSMISSION HUB SLEEVE NO. 2
(a) Check the sliding condition between the transmission hub sleeve No. 2 and transmission clutch hub No. 2.
(b) Check that the spline gear's edges of the transmission hub sleeve No. 2 is not worn down.
(c) Using vernier calipers, measure the width of the transmission hub sleeve No. 2 groove (B) and the thickness of the claw part on the gear shift fork No. 2 (A), and calculate the clearance.
Standard clearance (B - A): 0.15 to 0.35 mm (0.0059 to 0.0138 in.)
If the clearance is out of specification, replace the transmission hub sleeve No. 2 and gear shift fork No.2.
REASSEMBLY
1. INSPECT INPUT SHAFT
2. INSPECT 4TH GEAR
3. INSPECT 3RD GEAR
4. INSPECT 4TH GEAR SYNCHRONIZER RING
5. INSPECT 3RD GEAR SYNCHRONIZER RING
6. INSPECT TRANSMISSION HUB SLEEVE NO. 2
7. INSTALL TRANSMISSION HUB SLEEVE NO. 2
(a) Coat the transmission hub sleeve No. 2 with gear oil, install it to the transmission clutch hub No. 2.
NOTICE: Do not set the transmission clutch hub sleeve No. 2 and the transmission clutch hub No. 2 in incorrect orientation.
(b) Using a screwdriver, install the 3 synchromesh key springs with 3 synchromesh shifting keys to the transmission clutch hub No. 2.
8. INSTALL 3RD GEAR NEEDLE ROLLER BEARING
(a) Coat the 3rd gear needle roller bearing with gear oil, install it to the input shaft.
9. INSTALL 3RD GEAR
(a) Coat the 3rd gear with gear oil, install it to the input shaft.
10. INSTALL 3RD GEAR SYNCHRONIZER RING
(a) Coat the 3rd gear synchronizer ring with gear oil, install it to the 3rd gear.
11. INSTALL TRANSMISSION CLUTCH HUB NO. 2
(a) Using SST and a press, install the transmission clutch hub No. 2 to the input shaft.
SST 09316-60011 (09316-00021)
(b) Select a snap ring from the table below that will make the thrust clearance of the transmission clutch hub No. 2 below 0.1 mm (0.004 in.)
Snap ring thickness:
(c) Using a brass bar and a hammer, tap in the snap ring.
NOTICE: Take care not to damage the journal surface of the input shaft.
12. INSTALL 4TH GEAR SYNCHRONIZER RING
(a) Coat the 4th gear synchronizer ring with gear oil, install it to the transmission clutch hub No. 2.
13. INSTALL 4TH GEAR NEEDLE ROLLER BEARING
(a) Coat the 4th gear needle roller bearing and 4th gear bearing spacer with gear oil, install them to the input shaft.
14. INSTALL 4TH GEAR
(a) Coat the 4th gear with gear oil, install it to the input shaft.
15. INSTALL INPUT SHAFT REAR RADIAL BALL BEARING
(a) Using SST and a press, install the input shaft rear radial ball bearing to the input shaft.
SST 09636-20010
(b) Select a snap ring from the table below that will make the thrust clearance of the input shaft rear radial ball bearing below 0.1 mm (0.004 in.)
Snap ring thickness:
(c) Using a brass bar and a hammer, tap in the snap ring.
NOTICE: Take care not to damage the journal surface of the snap ring.
16. INSPECT 3RD GEAR RADIAL CLEARANCE
17. INSPECT 4TH GEAR RADIAL CLEARANCE
18. INSPECT 3RD GEAR THRUST CLEARANCE
19. INSPECT 4TH GEAR THRUST CLEARANCE