Input Shaft: Assembly

NOTE: Depending on date of manufacture, some input shafts will utilize a needle bearing under the 3rd and 4th Speed Gears.

NOTE: When servicing the input shaft assembly, all snap rings MUST be replaced with new ones upon assembly. 5th gear nut must also be replaced.

NOTE: When installing 3/4 synchronizer hub to shaft, make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub journal.

NOTE: Refer to (Fig 1 ) for input shaft assembly reference.

Install input shaft into fixture 8487.
Install thrust washer if removed upon disassembly.
Install 3rd gear and needle bearing (if equipped) (Fig 2 ).
Install 3rd gear blocker ring (Fig 3 ).

Fig 1: Identifying Components Of Input Shaft assembly
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Fig 2: Identifying 3rd Gear
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Fig 3: Identifying 3rd Gear Blocker Ring
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Install 3/4 synchronizer (Fig 4 ). When installing 3/4 synchronizer hub to shaft, make sure to align oil slots on synchronizer hub face with oil hole in the shaft splined hub journal.

Fig 4: Installing 3/4 Synchro Assembly
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Install NEW 3/4 synchronizer snap ring (Fig 5 ).

Fig 5: Installing 3/4 Synchro Snap Ring
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Install 4th gear blocker ring (Fig 6 ).

Fig 6: Installing 4th Gear Blocker Ring
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Install 4th gear and needle bearing (if equipped) (Fig 7 ).

Fig 7: Installing 4th Gear Removal/Installation
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Install 5th gear and press into position using installer 8481 (Fig 8 ).

Fig 8: Installing 5th Gear Installation
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Install NEW 5th gear nut and torque to 262 N.m (193 ft. lbs.) using wrench 8478 (Fig 9 ).

Fig 9: Installing 5th Gear Nut
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Stake 5th Gear nut in four (4) places as follows:
1. Install staking tool 8479 to 5th gear nut.
2. Tighten upper thumb screw by hand (Fig 10 ).
3. Tighten two (2) side thumb screws by hand.
  
  Fig 10: Identifying Staking Tool Set-Up
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4. Tighten both staking screws until they bottom on tool body (Fig 11 ).
  
  Fig 11: Tightening Stake Screws
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5. Loosen staking screws and thumb screws. Remove tool and visually inspect stake (Fig 12 ).
  
  Fig 12: Identifying 5th Gear Nut Stake (Four Places)
  Courtesy of DAIMLERCHRYSLER CORP.
6. Remove tool, rotate 90°, and repeat process to stake in four (4) places.
NOTE: The input shaft sealed roller bearing and snap ring do not get installed until transaxle assembly to facilitate installation of the reverse idler gear mechanism.