Input Shaft: Disassembly

CAUTION: When pressing off components, hold the shaft so that it does not fall.

Measure the input shaft clearances.
1. Measure the clearance between the third and second gears.
2. Measure the clearance between fourth gear and the bearing cone.
Fig 1: Measuring Input Shaft Clearances
Using the special tools and a press, press off the bearing (fourth gear end).

Fig 2: Removing Fourth Gear End Bearing

CAUTION: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.

Fig 3: Removing Fourth Gear And The Synchronizer Blocking Ring

CAUTION: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.

NOTE: Inspect all the synchronizer components for wear and damage; refer to SYNCHRONIZERS .

Fig 5: Removing Synchronizer Hub Assembly, Synchronizer Blocking Ring, And Third Gear

Using the special tools and a press, press off the synchronizer hub assembly, synchronizer blocking ring, and third gear.
Using the special tools and a press, press off the bearing (third gear end).

Fig 6: Removing Third Gear End Bearing
Measure input shaft gear runout.
- Inspect the input shaft for worn or damaged gears.
Fig 7: Measuring Input Shaft Gear Runout

NOTE: Set the synchronizer ring squarely in the gear, then measure around the circumference.

Fig 8: Inspecting Synchronizer Blocking Rings

Inspect the synchronizer blocking rings.
- Measure the clearance from the side of the gear.
- Inspect for smooth engagement with the gear.
- Inspect for worn or damaged teeth or tapper surface.
Inspect the synchronizer hub.
- Inspect for worn or damaged splines, synchronizer insert groove or end surface.
- Inspect for smooth hub sleeve movement when it is installed.
Measure the clearance between the third/fourth synchronizer hub and its shift fork.

Fig 9: Measuring Clearance Between Third/Fourth Synchronizer Hub And Shift Fork