Input Shaft, Transmission: Disassembly: Disassembly

WARNING: This page is about a different variant/trim than selected.

Fig 1: Identifying Input Shaft & Components

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1 - INPUT SHAFT

2 - STOP RING

3 - SLEEVE

4 - 5TH SPEED GEAR

5 - STOP RING

6 - SLEEVE

7 - 4TH SPEED GEAR

8 - STOP RING

9 - 3RD SPEED GEAR

NOTE:

Ring gaps must be measured with synchronizer ring biased towards gear clutching teeth on gear cone as much as possible while measuring gaps.

Before disassembly of the input shaft (1), it is necessary to check the synchronizer stop ring gap. Use a feeler gauge to measure the gaps between the stop rings (2, 5, and 8) and the speed gears. The correct gaps are listed below:

3rd - 0.73-1.53 mm (0.029-0.060 in)
4th - 0.77-1.57 mm (0.030-0.062 in).
5th - 0.73-1.53 mm (0.029-0.060 in)
Reverse Brake - 0.505-1.74 mm (0.020-0.068 in.)

The reverse brake measurement is taken between the stop ring and case.

If a stop ring gap does not fall within the specifications, it must be inspected for wear and replaced. If the 1st or 2nd synchronizer stop ring is worn beyond specifications, the complete output shaft assembly must be replaced.

The input shaft incorporates the 3rd, 4th, and 5th speed gears and synchronizers on the assembly.

Fig 2: 5th Synchro And Hub Snap Ring Removal/Installation

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1 - SNAP RING PLIERS

2 - INPUT SHAFT

3 - BEARING SPLITTER

4 - SNAP RING

Install Bearing Splitter (special tool #1130, Splitter, Bearing/Gear) (3) behind 5th speed gear. Remove snap ring (4) at 5th synchronizer hub on input shaft (2).

Fig 3: Removing Synchronizer & Gear Using Shop Press

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1 - PRESS RAM

2 - INPUT SHAFT

3 - BEARING SPLITTER

4 - SYNCHRONIZER ASSEMBLY

Remove synchronizer (4) and gear using shop press (1).

Fig 4: Caged Needle Bearing Removal/Installation
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1 - INPUT SHAFT

2 - CAGED NEEDLE BEARING
Remove caged needle bearing (2).

Fig 5: Split Thrust Washer Ring
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1 - SPLIT THRUST WASHER RING

2 - INPUT SHAFT
Remove 4-5 gears split thrust washer ring (1).

Fig 6: Split Thrust Washer Removal/Installation
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1 - INPUT SHAFT

2 - SPLIT THRUST WASHER

Remove split thrust washer (2).

Fig 7: Split Thrust Washer Separation Pin

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1 - SEPARATION PIN

2 - INPUT SHAFT

3 - PLIERS

Remove split thrust washer separation pin (1).

Fig 8: 4th Gear Removal
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1 - INPUT SHAFT

2 - 4TH GEAR
Remove 4th gear (2).

Fig 9: Caged Needle Bearing Removal
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1 - INPUT SHAFT

2 - CAGED NEEDLE BEARING

Remove 4th gear caged needle bearing (2). Check the caged needle bearing (2) for a broken retention spring.

Fig 10: 3-4 Synchronizer Hub Snap Ring

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1 - SNAP RING PLIERS

2 - SYNCHRO SNAP RING

3 - SYNCHRONIZER ASSEMBLY

Remove blocking ring. Remove 3-4 synchronizer hub retaining snap ring (3).

Fig 11: 3rd Gear Removal

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1 - PRESS RAM

2 - INPUT SHAFT

3 - 3RD GEAR

4 - SYNCHRONIZER ASSEMBLY

Install input shaft in shop press (1). Using Bearing Splitter (special tool #1130, Splitter, Bearing/Gear), remove 3-4 synchronizer and 3rd gear (3).

Fig 12: 3rd Gear Caged Needle Bearing
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1 - INPUT SHAFT

2 - 3RD GEAR CAGED NEEDLE BEARING
Remove 3rd gear caged needle bearing (2). Inspect needle bearing for a broken retention spring.
Inspect the input shaft for worn or damaged bearing races or chipped gear teeth. Replace as necessary.