Input shaft (five-speed gearbox)

PROCEDURE

Input shaft adjustment 1 – support; 2 – stand; 3 – dial indicator; 4 – indicator plunger; 5 – plate; 6 – input shaft; 7 – gearbox housing

Disassembly PROCEDURE 1. Press out tapered roller bearing 63 (see illustration Gearbox type 085). 2. Remove tapered roller bearing 49. 3. Remove thrust washer 50. 4. Remove 4th gear 52, needle bearing 51 and synchro blocking ring 53. 5. Remove circlip 54. 6. Press 3rd gear 60 off the input shaft together with synchro blocking ring 59 and synchronizer hub 56 (with sliding sleeve). 7. Remove circlip 58. 8. Remove needle bearing 61. Assembly PROCEDURE 1. Lubricate needle bearing 61 and install it on input shaft 62. 2. Install circlip 58. 3. Check the clearance between synchro blocking rings 53 and 59 and their corresponding gears 52 and 60. 4. Install 3rd gear 60 and synchro blocking ring 59 on input shaft 62. 5. Press on the assembled synchronizer 56 (if the synchronizer was disassembled, see subsection 5.2.2.2) so that the long part of the hub splines faces 4th gear, and the synchro keys engage the slots of the blocking ring. 6. Install circlip 54. 7. Install synchro blocking ring 53, making sure the synchro keys engage the slots of the blocking ring. 8. Lubricate needle bearing 51 and install it on input shaft 62. 9. Install 4th gear 52. 10. Install thrust washer 50. 11. Install tapered roller bearing 49. 12. Press tapered roller bearing 63 onto the shaft, applying force to the inner bearing race. Input shaft axial clearance adjustment Caution Adjust after replacing any of the following: gearbox housing, clutch housing, input shaft or input shaft tapered roller bearings.

subsection 5.2.2.2) so that the long splined part of the hub faces the 4th gear wheel and the synchronizer keys engage the grooves of the blocking ring. 6. Install the snap ring 54. 7. Install the synchronizer blocking ring 53, making sure the synchronizer keys engage the grooves of the blocking ring. 8. Lubricate the needle bearing 51 and install it on the input shaft 62. 9. Install the 4th gear 52. 10. Install the thrust washer 50. 11. Install the tapered roller bearing 49. 12. Press the tapered roller bearing 63 onto the shaft, applying force to the inner race of the bearing. Adjusting the input shaft end play. Warning: Adjustment is performed after replacing any of the following parts: transmission case, clutch housing, input shaft or input shaft tapered roller bearings.

PROCEDURE 1. Press outer race 3 (see illustration Clutch housing) of the tapered roller bearing out of clutch housing 2. 2. Remove adjusting shim 4 and press bearing race 3 back in. 3. Install the input shaft, join the clutch housing to the gearbox housing and tighten bolts 14 (see illustration Gearbox housing) to 25 N·m. 4. Turn the input shaft several times to seat the bearings. 5. Stand the gearbox vertically with the 5th gear end of the shaft facing up. 6. Install support 1 (see illustration Input shaft adjustment) with stand 2 and dial indicator 3 onto gearbox housing 7. 7. Place ground plate 5 under indicator plunger 4 on input shaft 6. 8. Move input shaft 6 axially from stop to stop and read the dial indicator. 9. Select an adjusting shim of the required size based on the axial clearance (difference between the indicator readings). 10. Remove the dial indicator, stand and support. 11. Disassemble the housing and press the bearing outer race out of the clutch housing. 12. Install the selected adjusting shim into the clutch housing and press the outer bearing race in. 13. Assemble the gearbox and check again. Axial clearance must be within 0.1–0.12 mm. Measured axial clearance, mm / Adjusting shim thickness, mm: up to 0.68 / 0.65; 0.68 – 0.75 / 0.7; 0.74 – 0.78 / 0.75; 0.79 – 0.83 / 0.8; 0.84 – 0.88 / 0.85; 0.89 – 0.93 / 0.9; 0.94 – 0.98 / 0.95; 0.99 – 1.03 / 1.00; 1.04 – 1.08 / 1.05; 1.09 – 1.13 / 1.10; 1.14 – 1.18 / 1.15; 1.19 – 1.23 / 1.20; 1.24 – 1.28 / 1.25; 1.29 – 1.33 / 2 x 0.65; 1.34 – 1.38 / 0.65 + 0.7; 1.39 – 1.43 / 2 x 0.7; 1.44 – 1.48 / 0.7 + 0.75; 1.49 – 1.53 / 2 x 0.75; 1.54 – 1.58 / 0.75 + 0.8; 1.59 – 1.63 / 2 x 0.8; 1.63 – 1.68 / 0.8 + 0.85; 1.69 – 1.75 / 2 x 0.85