5B
Input Shaft Assembly Disassembly and Assembly
Reference: Input Shaft, Countershaft and Output Shaft Components:K9K Model
Disassembly
1) Remove snap ring.
2) Remove input shaft front bearing (1) using bearing puller and press, and then remove input shaft front bearing circlip.
3) Remove input shaft union.
4) Hold part of reverse gear of input shaft assembly (1) with vise (2) through woodblock (4), remove input shaft 5th hub nut (3).
5) Apply bearing puller to 4th gear (1), and drive out 5th speed synchronizer hub (2), 3rd gear (3), high speed gear needle bearings, 3rd gear bush, high speed synchronizer assembly (4) and 4th gear all at once from input shaft using metal stick (5) and press.
CAUTION:
To avoid gear teeth from being damaged, support 4th gear at flat side of bearing puller.
Assembly
Reference: Input Shaft Assembly Inspection:K9K Model
1) Clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary.
2) To ensure lubrication, air blow oil holes (1) and make sure that they are free from any obstruction.
3) Drive in input shaft front bearing (1) to input shaft using special tool and hammer and then install snap ring.
Special Tool
(A) : 09940–51710
NOTE:
Input shaft front bearing circlip (2) must be installed before input shaft front bearing is installed.
4) Apply oil to high speed gear needle bearing, and then install needle bearing to input shaft.
Install 4th gear and high speed synchronizer ring.
5) Assemble synchronizer sleeve (4) and hub (3) as follows.
a) Fit high speed synchronizer sleeve to hub in specified direction as shown in the figure.
b) Insert 3 keys (2) to hub.
c) Set springs (1) at specified position as shown in the figure.
Synchronizer key installation position
A = B
[A]: 4th gear side D: Projecting end
C: Key way 5. 4th gear
6) Drive in high speed synchronizer assembly (1) using special tool and hammer.
NOTE:
• While press-fitting sleeve &hub, make sure that synchronizer ring key slots (2) are aligned with keys in sleeve & hub assembly.
• Check free rotation of 4th gear after press fitting sleeve & hub assembly.
Special Tool
(A) : 09913–84510
7) Apply oil to high speed gear needle bearing, and then install 3rd gear bush (1), high speed gear needle bearing (2) and 3rd gear (3).
4. 4th gear
8) Press-fit 5th speed synchronizer hub (1) using special tool and hammer.
Special Tool
(A) : 09913–84510
9) Tighten input shaft 5th hub nut to specified torque in the same manner as Step 4) of “Disassembly” in Input Shaft Assembly Disassembly and Assembly:K9K Model .
Tightening torque
Input shaft 5th hub nut : 210 N·m ( 21.0 kg-m, 152.0 lb-ft)
10) Caulk input shaft 5th hub nut (2) using caulking tool.
11) Drive in new input shaft union (1) using puller and hydraulic press.