Input Shaft: Service and Repair: Description and Operation
Input Shaft Assembly Overview
Input Shaft, Removing and installing, refer to => [ Transmission, Assembly Sequence ] Disassembly and Assembly
Disassembling and assembling input shaft - assembly sequence => [ Input Shaft ] Disassembly and Assembly
• Pay attention to the technical data when installing new gears or a new input shaft.
• Lubricate all bearings with gear oil when inserting on input shaft.
• After installing, the 3rd through 6th gears must have an axial play of 0.15 to 0.50 mm.
• If the synchronizer rings are not to be replaced, make sure they are reallocated to their original gear.
1 Transmission cover
2 Thrust washer
• Installation position: the rounded side on the inner diameter faces the transmission cover, refer to => [ (Item 1) Transmission cover ]
3 Roller bearing
4 Inner race
• For roller bearing
5 Thrust washer
• Installation position: chamfer faces the bearing housing, refer to => [ (Item 6) Bearing housing ]
6 Bearing housing
• Disassembling and assembling, refer to => [ Bearing Housing Assembly Overview ] Bearing Housing Assembly Overview
7 Input shaft
8 Transmission housing
9 4th gear wheel
10 Needle bearing
• For 4th gear
• Quantity: 2
11 4th gear inner race
12 4th gear intermediate ring
13 4th gear synchronizer ring
14 Locking collar for 3rd and 4th gear
• Mark the installation position on the synchronizer hub before removing it
• Checking for wear, refer to => [ Locking Collar for 3rd to 6th Gears, Checking
for Wear ]
15 Securing ring
• For 3rd and 4th gears synchronizer hub
16 Locking piece
• Quantity: 3
17 Ball
• Quantity: 3
18 Spring
• Quantity: 3
19 Synchronizer hub for 3rd and 4th gears
• Mark installation position
• Pressing off, refer to => [ Removing the synchronizer hub with the 3rd and
4th gear locking collar ] Disassembly and Assembly
• Pressing on, refer to => [ Pressing on synchronizer hub with locking collar
for 3rd and 4th gears ] Disassembly and Assembly
20 Synchronizer ring for 3rd gear
21 Large intermediate ring
• For 3rd gear
22 3rd gear intermediate ring
23 Small intermediate ring
• For 3rd gear
24 3rd gear wheel
25 Needle bearing
• For 3rd gear
26 Securing ring
• For the thrust washer => [ (Item 27) Two-piece thrust washer ]
• Removing, refer to => [ Removing the locking ring and
side thrust washers ] Disassembly and Assembly
• Installing, refer to => [ Installing the locking ring and
two-piece thrust washer ] Disassembly and Assembly
27 Two-piece thrust washer
• Removing, refer to => [ Removing the locking ring and
side thrust washers ] Disassembly and Assembly
• Installing, refer to => [ Installing the locking ring and
two-piece thrust washer ] Disassembly and Assembly
28 6th gear wheel
29 Needle bearing
• For 6th gear
30 6th gear inner race
31 6th gear intermediate ring
32 Synchronizer ring for 6th gear
33 Locking collar for 5th and 6th gear
• Mark the installation position on the synchronizer hub before removing it
• Checking for wear, refer to => [ Locking Collar for 3rd to 6th Gears, Checking
for Wear ]
34 Thrust ring
• Installation location, refer to => [ Installation position, 5th and 6th gear synchronizer
hub locking ring and thrust ring ] Disassembly and Assembly
35 Securing ring
• For 5th and 6th gears synchronizer hub
• Installation location, refer to => [ Installation position, 5th and 6th gear synchronizer
hub locking ring and thrust ring ] Disassembly and Assembly
36 Locking piece
• Quantity: 3
37 Ball
• Quantity: 3
38 Spring
• Quantity: 3
39 Synchronizer hub for 5th and 6th gears
• Mark installation position
• Pressing off, refer to => [ Removing the synchronizer hub with the 5th and
6th gear locking collar ] Disassembly and Assembly
• Pressing on, refer to => [ Pressing on synchronizer hub with locking collar
for 5th and 6th gears ] Disassembly and Assembly
40 Synchronizer ring for 5th gear
41 5th gear intermediate ring
42 5th gear inner race
43 5th gear wheel
44 Needle bearing
• For 5th gear
45 Input Shaft
Locking Collar for 3rd to 6th Gears, Checking for Wear
• Replace any worn locking collars. Refer to => [ Input Shaft ] Disassembly and Assembly.