Input Shaft: Disassembly

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

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

Invert input shaft assembly and place in fixture 8487.
Remove input bearing snap ring (Fig 1 ).
Remove input bearing. Place input shaft assembly onto arbor press table, with the input bearing supported by bearing splitter (Fig 2 ). Using adapter 8486 - 4, press bearing off of shaft, while helper supports shaft to prevent dropping.

Fig 1: Removing Input Bearing Snap Ring
Courtesy of DAIMLERCHRYSLER CORP.

Fig 2: Removing Input Bearing
Courtesy of DAIMLERCHRYSLER CORP.
Place input shaft assembly back into fixture 8487. Secure fixture to bench with fasteners, or secure to bench vise.
NOTE: 5th gear nut is staked to the shaft. If necessary, grind stake area to ease removal, but use care not to contact gear.
Remove 5th gear nut with wrench 8478 (Fig 3 ). Discard nut and use a new one upon assembly.

Fig 3: Removing 5th Gear Nut
Courtesy of DAIMLERCHRYSLER CORP.
Remove 5th gear with arbor press and bearing splitter.
Remove 4th gear and needle bearing (if equipped) (Fig 4 ).

Fig 4: Removing 4th Gear
Courtesy of DAIMLERCHRYSLER CORP.
Remove 4th gear blocker ring (Fig 5 ).

Fig 5: Removing 4th Gear Blocker Ring
Courtesy of DAIMLERCHRYSLER CORP.
Remove 3/4 synchronizer snap ring (Fig 6 ). Discard and replace with new snap ring upon assembly.

Fig 6: Removing 3/4 Synchro Snap Ring
Courtesy of DAIMLERCHRYSLER CORP.
Remove 3/4 synchronizer (Fig 7 ).

Fig 7: Removing 3/4 Synchro Assembly
Courtesy of DAIMLERCHRYSLER CORP.
Remove 3rd gear blocker ring (Fig 8 ).

Fig 8: Removing 3rd Gear Blocker Ring
Courtesy of DAIMLERCHRYSLER CORP.
Remove 3rd gear and needle bearing (if equipped) (Fig 9 ).
Inspect third gear thrust washer for signs of excessive wear. To replace, drive off of input shaft with suitable drift and hammer.

Fig 9: Removing 3rd Gear
Courtesy of DAIMLERCHRYSLER CORP.