INPUT SHAFT DISASSEMBLY

PROCEDURE

1. INSPECT 3RD GEAR THRUST CLEARANCE

   Click here

2. INSPECT 5TH GEAR THRUST CLEARANCE

   Click here

3. INSPECT 3RD GEAR RADIAL CLEARANCE

   Click here

4. INSPECT 4TH GEAR RADIAL CLEARANCE

   Click here

5. INSPECT 5TH GEAR RADIAL CLEARANCE

   Click here

6. REMOVE 5TH GEAR

   1. 

      Using SST and a press, remove the rear input shaft radial ball bearing, No. 3 transmission hub sleeve, No. 3 transmission clutch hub, 5th gear synchronizer ring and 5th gear from the input shaft.

      09950-00020

      09612-24014

      09612-10061

      Note:

      • Do not excessively tighten SST.

      • Support the input shaft by hand to prevent it from dropping.

      Tip:

      Insert the claws of SST between the 4th gear and 5th gear as shown in the illustration.

7. REMOVE NO. 3 TRANSMISSION CLUTCH HUB

   1. 

      *1	No. 3 Shifting Key Spring
      *2	No. 3 Transmission Hub Sleeve
      *3	No. 3 Shifting Key
      *4	No. 3 Transmission Clutch Hub

      Remove the 2 No. 3 shifting key springs from the No. 3 transmission clutch hub.

   2. Remove the No. 3 transmission hub sleeve from the No. 3 transmission clutch hub.

   3. Remove the 3 No. 3 shifting keys from the No. 3 transmission clutch hub.

8. REMOVE 5TH GEAR NEEDLE ROLLER BEARING

   1. 

      Remove the 5th gear needle roller bearing from the input shaft.

9. REMOVE 5TH GEAR BEARING SPACER

   1. 

      Remove the 5th gear bearing spacer from the input shaft.

10. INSPECT 4TH GEAR THRUST CLEARANCE

    Click here

11. REMOVE 5TH GEAR SHAFT SNAP RING

    1. 

       Using a snap ring expander, remove the 5th gear shaft snap ring from the input shaft.

       Note:

       Be careful not to damage the journal surface of the input shaft.

12. REMOVE 5TH GEAR THRUST WASHER

    1. 

       Remove the 5th gear thrust washer from the input shaft.

13. REMOVE 5TH GEAR THRUST WASHER BALL

    1. 

       Using a Magnet Hand, remove the 5th gear thrust washer ball from the input shaft.

14. REMOVE 4TH GEAR

    1. 

       Remove the 4th gear from the input shaft.

15. REMOVE 4TH GEAR NEEDLE ROLLER BEARING

    1. 

       Remove the 4th gear needle roller bearing from the input shaft.

16. REMOVE 4TH GEAR BEARING SPACER

    1. 

       Remove the 4th gear bearing spacer from the input shaft.

17. REMOVE 4TH GEAR SYNCHRONIZER RING

    1. 

       Remove the 4th gear synchronizer ring from the No. 2 transmission clutch hub.

18. REMOVE NO. 2 CLUTCH HUB SETTING SHAFT SNAP RING

    1. 

       Using 2 screwdrivers and a hammer, remove the No. 2 clutch hub setting shaft snap ring from the input shaft.

       Tip:

       Use a piece of cloth to keep the snap ring from flying off.

19. REMOVE 3RD GEAR

    1. 

       Using SST and a press, remove the No. 2 transmission hub sleeve, No. 2 transmission clutch hub, 3rd gear synchronizer ring and 3rd gear from the input shaft.

       09950-00020

       Note:

       • Do not excessively tighten SST.

       • Support the input shaft by hand to prevent it from dropping.

20. REMOVE NO. 2 TRANSMISSION CLUTCH HUB

    1. 

       *1	No. 2 Shifting Key Spring
       *2	No. 2 Transmission Hub Sleeve
       *3	No. 2 Shifting Key
       *4	No. 2 Transmission Clutch Hub

       Remove the 2 No. 2 shifting key springs from the No. 2 transmission clutch hub.

    2. Remove the No. 2 transmission hub sleeve from the No. 2 transmission clutch hub.

    3. Remove the 3 No. 2 shifting keys from the No. 2 transmission clutch hub.

21. REMOVE 3RD GEAR NEEDLE ROLLER BEARING

    1. 

       Remove the 3rd gear needle roller bearing from the input shaft.

22. REMOVE FRONT INPUT SHAFT BEARING

    1. 

       Using SST and a press, remove the front input shaft bearing from the input shaft.

       09950-00020

       Note:

       Support the input shaft by hand to prevent it from dropping.