Input Shaft: Disassembly

Before disassembly of the input shaft, it is necessary to check the synchronizer stop ring gap. Use a feeler gauge to measure the gaps between the stop rings and the speed gears. The correct gaps are listed as follows:

• 1st - 0.522-2.208 mm (0.021-0.087 in)
• 2nd - 0.522-2.208 mm (0.021-0.087 in)
• 3rd - 0.73-1.53 mm (0.029-0.060 in)
• 4th - 0.77-1.57 mm (0.030-0.062 in).
• 5th - 0.73-1.53 mm (0.029-0.060 in)

If a stop ring gap does not fall within the specifications, it must be inspected for wear and replaced. If the 1st or 2nd synchronizer stop ring is worn beyond specifications, the complete output shaft assembly must be replaced.

The input shaft incorporates the 3rd, 4th, and 5th speed gears and synchronizers on the assembly. (Fig 1).

Fig 1: Removing Input Shaft

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1. Install bearing splitter behind 5th speed gear. Remove snap ring at 5th synchronizer hub on input shaft. (Fig 2).
   Fig 2: Removing 5th Synchro & Hub Snap Ring

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2. Remove synchronizer and gear using shop press. (Fig 3).
   Fig 3: Removing Synchronizer Using Shop Press

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3. Remove caged needle bearing. (Fig 4).
   Fig 4: Removing Caged Needle Bearing

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4. Remove 4-5 gears split thrust washer ring. (Fig 5).
   Fig 5: Removing Split Thrust Washer Ring

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5. Remove split thrust washer. (Fig 6).
   Fig 6: Removing Split Thrust Washer

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6. Remove split thrust washer separation pin. (Fig 7).
   Fig 7: Removing Split Thrust Washer Separation Pin

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7. Remove 4th gear. (Fig 8).
   Fig 8: Removing 4th Gear

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8. Remove 4th gear caged needle bearing. (Fig 9). Check the caged needle bearing for a broken retention spring.
   Fig 9: Removing Caged Needle Bearing

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9. Remove blocking ring. Remove 3-4 synchronizer hub retaining snap ring. (Fig 10).
   Fig 10: Removing 3-4 Synchronizer Hub Snap Ring

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10. Install input shaft in shop press. Using bearing splitter, remove 3-4 synchronizer and 3rd gear. (Fig 11).
    Fig 11: Removing 3rd Gear

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11. Remove 3rd gear caged needle bearing. (Fig 12). Inspect needle bearing for a broken retention spring
    Fig 12: Removing 3rd Gear Caged Needle Bearing

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12. Inspect the input shaft for worn or damaged bearing races or chipped gear teeth. Replace as necessary.