INPUT SHAFT DISASSEMBLY

PROCEDURE

  1. INSPECT 6TH GEAR THRUST CLEARANCE

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  2. INSPECT 5TH GEAR THRUST CLEARANCE

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  3. INSPECT 4TH GEAR THRUST CLEARANCE

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  4. INSPECT 3RD GEAR THRUST CLEARANCE

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  5. INSPECT 6TH GEAR RADIAL CLEARANCE

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  6. INSPECT 5TH GEAR RADIAL CLEARANCE

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  7. INSPECT 4TH GEAR RADIAL CLEARANCE

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  8. INSPECT 3RD GEAR RADIAL CLEARANCE

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  9. REMOVE REAR INPUT SHAFT BEARING SHAFT SNAP RING

    1. C194229

      Using a snap ring expander, remove the rear input shaft bearing shaft snap ring.

  10. REMOVE 6TH GEAR SUB-ASSEMBLY

    1. C194230E09

      Using SST and a press, remove the rear input shaft radial ball bearing and 6th gear from the input shaft.

      09950-00020

      09950-60010

      09951-00270

      09950-70010

      09951-07100

      Note:

      • Do not tighten SST excessively.

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

  11. REMOVE 6TH GEAR NEEDLE ROLLER BEARING

    1. C194231

      Remove the 2 pieces of the 6th gear needle roller bearing from the inner 6th gear bearing race.

  12. REMOVE NO. 5 SYNCHRONIZER RING

    1. C194232

      Remove the No. 5 synchronizer ring from the No. 3 transmission clutch hub.

  13. REMOVE INNER 6TH GEAR BEARING RACE

    1. C194233

      Remove the inner 6th gear bearing race from the input shaft.

  14. REMOVE INNER 6TH GEAR BEARING RACE LOCK BALL

    1. C194234E07

      Using a magnet hand, remove the inner 6th gear bearing race lock ball from the input shaft.

      Table 1. Text in Illustration

      *1

      Magnet Hand

  15. REMOVE NO. 3 TRANSMISSION HUB SLEEVE

    1. C194235

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

  16. REMOVE NO. 3 SYNCHROMESH SHIFTING KEY

    1. C194236

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

  17. REMOVE 5TH GEAR

    1. C194237E12

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

      09950-00020

      Note:

      • Do not tighten SST excessively.

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

  18. REMOVE 5TH GEAR NEEDLE ROLLER BEARING

    1. C194238

      Remove the 2 pieces of the 5th gear needle roller bearing from the inner 5th gear bearing race.

  19. REMOVE INNER 5TH GEAR BEARING RACE

    1. C194239

      Remove the inner 5th gear bearing race from the input shaft.

  20. REMOVE INNER 5TH GEAR BEARING RACE LOCK BALL

    1. C194240E03

      Using a magnet hand, remove the inner 5th gear bearing race lock ball from the input shaft.

      Table 2. Text in Illustration

      *1

      Magnet Hand

  21. REMOVE 4TH GEAR

    1. C194241

      Remove the 4th gear from the input shaft.

  22. REMOVE 4TH GEAR NEEDLE ROLLER BEARING

    1. C194242

      Remove the 2 pieces of the 4th gear needle roller bearing from the input shaft.

  23. REMOVE OUTER 2ND SYNCHRONIZER RING

    1. C194243

      Remove the outer 2nd synchronizer ring from the No. 2 transmission clutch hub.

  24. REMOVE 4TH GEAR BEARING SPACER

    1. C194244

      Remove the 4th gear bearing spacer from the No. 2 transmission clutch hub.

  25. REMOVE NO. 2 TRANSMISSION HUB SLEEVE

    1. C194245

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

  26. REMOVE NO. 2 SYNCHROMESH SHIFTING KEY

    1. C194236

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

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

    1. C194247

      Using a snap ring expander, remove the No. 2 clutch hub setting shaft snap ring.

  28. REMOVE 3RD GEAR

    1. C194248E11

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

      09950-00020

      Note:

      • Do not tighten SST excessively.

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

  29. REMOVE 3RD GEAR NEEDLE ROLLER BEARING

    1. C194249

      Remove the 2 pieces of the 3rd gear needle roller bearing from the input shaft.

  30. REMOVE FRONT INPUT SHAFT BEARING

    1. C194250

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

      Note:

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