Input Shaft Disassembly and Reassembly

Input Shaft Disassembly and Reassembly
Reference: Manual Transaxle Assembly Disassembly and Reassembly
Reference: Input Shaft Components

Disassembly
1) Remove circlip (1) using special tool.

Special Tool
(A): 09900-06107





2) Remove input shaft right bearing (2) and left bearing (4) from input shaft (1) using bearing puller (3) and hydraulic press.








3) Remove 6th gear spacer (1) and 6th gear (2) from input shaft (4) using puller (3) and hydraulic press.

CAUTION:
To avoid gear tooth from being damaged, support it at flat side of bearing puller.





4) Remove 5th and 6th synchronizer sleeve & hub assembly (1) and 5th gear (2) using puller (3) and hydraulic press.





5) Remove 5th gear needle bearing from input shaft.
6) Remove 5th gear spacer according to the following procedure.
a) Engage high speed synchronizer sleeve to 4th gear.
b) Push down input shaft (1) a little using puller (2) and hydraulic press.





c) Remove 5th gear spacer (1) using puller (2) and hydraulic press.





7) Remove 4th gear, 4th gear synchronizer ring and 4th gear needle bearing from input shaft.
8) Remove circlip (1) using special tool.

Special Tool
(A): 09900-06107





9) Remove high speed synchronizer sleeve & hub assembly (1) and 3rd gear (2) from input shaft (4) using puller (3) and hydraulic press.

CAUTION:
To avoid gear tooth from being damaged, support it at flat side of bearing puller.





10) Remove 3rd gear needle bearing from input shaft.
11) Disassemble synchronizer sleeve & hub assembly.

Reassembly
Reference: Input Shaft Inspection
Reference: Gear Shift Shaft and Fork Inspection

1) Install right bearing (1) to input shaft (2) using special tool and hydraulic press.

Special Tool
(A): 09941-74910





2) Fit high speed synchronizer sleeve (1) to hub (2) and 3 keys (3) as shown in figure.

NOTE:
^ No specific direction is assigned to each key but it is assigned as sleeve & hub assembly.
^ Inside diameter at high speed synchronizer hub is larger than those of low speed synchronizer hub.

Synchronizer key installation position








3) Install 3rd gear needle bearing and apply transaxle oil to it, and then install 3rd gear synchronizer inner ring (2), 3rd gear synchronizer center cone (3), 3rd gear synchronizer outer ring (4) and 3rd gear (1) to input shaft.

NOTE:
Make sure claws on 3rd gear synchronizer center cone fit into the holes on 3rd gear.





4) Install high speed sleeve & hub assembly (3) using special tool and hydraulic press and then install circlip.

NOTE:
^ While press-fitting sleeve & hub, make sure that synchronizer ring key slots are aligned with keys (5) in sleeve & hub assembly.
^ Check free rotation of 3rd gear (1) after press-fitting sleeve & hub assembly.

Special Tool
(A): 09944-77030








5) Install 4th gear needle bearing (2) and apply transaxle oil to it, and then install synchronizer ring (4) and 4th gear (3).
6) Install 5th gear spacer (1) using special tools and hydraulic press.

CAUTION:
Use puller and hydraulic press that bears at least 5000 kgf (11023 lbf) safely.

Special Tool
(A): 09940-54910
(B): 09913-85210





7) Install 5th gear needle bearing and apply transaxle oil to it, and then install 5th gear and synchronizer ring.
8) Fit 5th & 6th gear synchronizer sleeve (1) to hub (2) and 3 keys (3) as shown in figure.

NOTE:
^ No specific direction is assigned to 5th & 6th gear synchronizer hub or each key but it is assigned as assembly.
^ Inside diameter at 5th & 6th gear synchronizer hub is smaller than those of low speed synchronizer hub.

Synchronizer key installation position








9) Install 5th & 6th gear synchronizer sleeve & hub assembly (1) using special tool and hydraulic press.

Special Tool
(A): 09913-85210








10) Install 6th gear needle bearing (1) and apply transaxle oil to it, and then install synchronizer ring (3) and 6th gear (2).
11) Install 6th gear spacer (4) using special tool and hydraulic press.

Special Tool
(A): 09913-85210





12) Press-fit left bearing (1) using special tool and hydraulic press.

Special Tool
(A): 09913-85210





13) Select circlip (1) that makes thrust clearance "a" of bearing 0.1 mm (0.004 in) or less and install it.





Available circlip thickness