Page 929 of 2103
MANUAL TRANSAXLE OVERHAUL
Input Shaft
4
q 5
6
11
Disassembly steps
1. Taper roller bearing 2. Bearing sleeve
3. Snap ring 4. Taper roller bearing
5. Snap ring 6. Cone spring 7. Sub gear
8.
speed gear9.Needle bearing 10. Bearing sleeve
11. Synchronizer ring 12. Synchronizer spring 13. synchronizer 14. Synchronizer key 15. hub
16. Synchronizer ring17. gear
18. Needle bearing1 9 . I n p u t s h a f t
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Page 930 of 2103
MANUAL TRANSAXLE OVERHAUL. Input Shaft
Disassembly
1. Taper roller bearing 2. Bearing sleeve 3. Snap ring 4. Taper roller bearing5.
speed gear6.Needle bearing 7. Bearing sleeve8.Synchronizer ring 9. Synchronizer spring 10. speed synchronizer sleeve
11.Synchronizer speed synchronizer
Synchronizer ring speed S n a p r i n g
Cone spring Sub gearNeedle bearingOil sealInput shaft
20.
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Page 931 of 2103
MANUAL TRANSAXLE OVERHAUL:
Input
D I S A S S E M B L Y
BALL BEARING TAPER
ROLLER BEARING, REMOVAL
I
speed gear
SLEEVE FOR SPEED GEAR
BALL BEARING TAPER ROLLER
BEARING
SPEED
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Page 932 of 2103
MANUAL TRANSAXLE OVERHAUL
Input Shaft
gear
spee
gear
side
Identificationmark
Spring
stepped
SPEED SYNCHRONIZER HUB
SPEED
INSTALLATION
SYNCHRONIZER SPRING
INSTALLATION
When installing the be sure position
each spring with respect to the keys illustrated.
SLEEVE FOR
INSTALLATION
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Page 933 of 2103
MANUAL TRANSAXLE’ OVERHAUL
Input
Snap ring
Sub
speedgear side
210019
,
GEAR CONE
INSTALLATION
SPACER INSTALLATION
REAR BALL
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Page 934 of 2103
MANUAL TRANSAXLE OVERHAUL
Input Shaft
2
8
22100024
2
Bearingsleeve
Select the thickest snap ring that be the snap
ring groove.
Standard value:Input shaft rear bearing
mm in.)
Caution
l Do not reuse the snap
lThe snap ring by pliers,
resulting in improper
the
SLEEVE FOR SPEED GEAR
INSTALLATION
Caution
When press-fitting the sleeve to the input shaft, m ake
sure that the sleeve flange is closely fitted to the bearing.
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Page 935 of 2103
M A N U A L
65133, Input Shaft
F R O N T B A LL
BEARING INSTALLATION
SNAP RING INSTALLATION’
Snap rings are available in three, Select
the thickest one that fits in the snap ring
Standard value:
input shaft front end play
mm in.)
Caution
Do not damage the input shaft seal
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Page 936 of 2103

M A N U A L T R A N S A X L E ’ O V E R H A U L
Shaft , ,
2 0 1 0 5 1
II
Synchronizer ringGear2110009
201044
INSPECTION
INPUT SHAFT
. . .
(1) Check the outer surface of the input shaft wher
e the
needle bearing is mounted for damage, abnormal wear
and seizure [portion A].
(2) Check the
for damage and wear.
NEEDLE BEARING
(1) Combine the needle bearing with the shaft or
sleeve and gear and check that it rotates smoothly without’
abnormal noise or play.
(2) Check the needle bearing cage for
SYNCHRONIZER RING
(1) Check the clutch gear teeth for and breakage.
(2) Check the internal surface for damage, and broken
threads.
(3) Force the synchronizer ring toward the clutch g ear and
check clearance “A”. Replace if it is out of specif ication.
Limit: 0.5 mm
in.)
SYNCHRONIZER SLEEVE AND HUB (1) Combine the synchronizer sleeve and hub and che ck
that they slide smoothly.
(2) Check that the sleeve is free from damage at it s inside
front and rear ends.
(3) Check for wear of the hub end surfaces (in cont act with
each speed gear).
Caution
When replacing, replace the synchronizer hub and sleeve as a set.
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