Input Shaft: Service and Repair

DISASSEMBLY





1. INSPECT 3RD AND 4TH GEARS THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
3rd gear: 0.10 - 0.35 mm (0.0039 - 0.0138 inch)
4th gear: 0.10 - 0.55 mm (0.0039 - 0.0217 inch)
Maximum clearance:
3rd gear: 0.35 mm (0.0138 inch)
4th gear: 0.55 mm (0.0217 inch)





2. INSPECT 3RD AND 4TH GEARS RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between the gear and shaft.
Standard clearance:
KOYO made: 0.015 - 0.058 mm (0.0006 - 0.0023 inch)
NSK made: 0.015 - 0.056 mm (0.0006 - 0.0022 inch)
Maximum clearance:
KOYO made: 0.058 mm (0.0023 inch)
NSK made: 0.056 mm (0.0022 inch)
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
3. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.





4. REMOVE REAR BALL BEARING, 4TH GEAR, NEEDLE ROLLER BEARING, SPACER AND SYNCHRONIZER RING FROM INPUT SHAFT
a) Using SST and a press, remove the rear ball bearing and 4th gear.
SST 09950-00020
b) Remove the needle roller bearings, spacer and synchronizer ring.
5. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.





6. REMOVE NO. 2 HUB SLEEVE ASSEMBLY, 3RD GEAR, SYNCHRONIZER RING AND NEEDLE ROLLER BEARING
a) Using SST and a press, remove the No. 2 hub sleeve assembly, 3rd gear and synchronizer ring.
SST 09950-00020
b) Remove the needle roller bearings.





7. DISASSEMBLE NO. 2 HUB SLEEVE ASSEMBLY
a) Using a screwdriver, remove the 2 shifting key springs and 3 shifting keys from the No. 2 clutch hub.
b) Remove the No. 2 hub sleeve from the No. 2 clutch hub.

INSPECTION





1. INSPECT SYNCHRONIZER RING
a) Check for wear or damage.
b) Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.

NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.

c) Check again the braking effect of the synchronizer ring.





d) Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
Minimum clearance: 0.75 mm (0.0295 inch)
If the clearance is less than the minimum, replace the synchronizer ring and apply a small amount of the fine lapping compound on gear cone.

NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.





2. INSPECT SHIFT FORK AND HUB SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
Maximum clearance: 0.35 mm (0.014 inch)
If the clearance exceeds the maximum, replace the shift fork or hub sleeve.





3. INSPECT INPUT SHAFT
a) Check the input shaft for wear or damage.
b) Using a micrometer, measure the outer diameter of the in put shaft journal surface.
Minimum outer diameter:
Part A: 24.885 mm (0.9797 inch)
Part B: 28.985 mm (1.1411 inch)
Part C: 30.985 mm (1.2199 inch)
Part D: 24.967 mm (0.9830 inch)
If the outer diameter is less than the minimum, replace the input shaft.





c) Using a dial indicator, check the shaft runout.
Maximum runout: 0.03 mm (0.0012 inch)
If the runout exceeds the maximum, replace the input shaft.

REASSEMBLY

HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.





1. ASSEMBLE NO. 2 HUB SLEEVE ASSEMBLY
a) Install the 3 shifting keys and No. 2 hub sleeve to the No. 2 clutch hub.
b) Install the 2 shifting key springs under the shifting keys.

NOTICE: Position the shifting key springs so that their end gaps are not in line.





2. INSTALL NEEDLE ROLLER BEARING, 3RD GEAR, SYNCHRONIZER RING AND NO. 2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT
a) Apply gear oil to the needle roller bearings and install it.
b) Install the 3rd gear and synchronizer ring.
c) Install the No. 2 hub sleeve assembly so that the synchronizer ring slots and shifting keys are aligned.





d) Using a press, install the No. 2 hub sleeve assembly.





3. INSTALL SNAP RING





a) Select a snap ring that allows the minimum axial play.
b) Using a screwdriver and hammer, tap in the snap ring.
4. INSPECT 3RD GEAR THRUST CLEARANCE





5. INSTALL SPACER, NEEDLE ROLLER BEARING, SYNCHRONIZER RING, 4TH GEAR AND REAR BALL BEARING
a) Install the spacer.
b) Apply gear oil to the needle roller bearings and install it.
c) Place the synchronizer ring on the No. 2 hub sleeve assembly and align the synchronizer ring slots with the shifting keys.
d) Install the 4th gear.





e) Using SST and a press, install the rear ball bearing.
SST 09608-00071





6. INSTALL SNAP RING





a) Select a snap ring that allows the minimum axial play.
b) Using a screwdriver and hammer, tap in the snap ring.
7. INSPECT 4TH GEAR THRUST CLEARANCE