1. Torx screws; 2. Bearing retainer plate; 3. Ball bearing; 4. Retaining ring; 5. Input shaft; 6. Thrust washer; 7. Belleville washers; 8. Fifth gear; 9. Fifth gear bush; 10. Thrust washer; 11. Circlip; 12. Third/fourth gear; 13. Circlip; 14. Second gear; 15. Circlip
Disassembly
1. Remove the circlip (15) from in front of second gear (14).
2. Remove second gear (14).
3. Remove the circlip (13) from in front of third/ fourth gear (12).
4. Remove third/fourth gear (12).
5. Remove the circlip (11) from in front of fifth gear (8).
6. Remove the thrust washer (10), fifth gear (8) and the fifth gear bush (9).
7. Note (or mark) the orientation of the two Belleville washers (7), then remove them from the shaft.
8. Remove the thrust washer (6).
Note: Unless the bearing at the clutch end of the input shaft is damaged or worn, it is not normally necessary to remove it from the shaft. The bearing is pressed onto the shaft and is also pressed into its housing and retained by a snap-ring. The bearing and housing are removed from the shaft together and are then separated.
Warning!
- When using a press, always wear overalls, eye face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body.
- Never wear loose clothing, which could become trapped in the press and cause crushing injury to the hand, arms or other parts of the anatomy.
9. Support the bearing and housing on press bars, then press the shaft through the bearing and housing as shown below.
1. Press bars; 2. Searing/housing
10. Remove the snap-ring from the bearing housing.
Caution! When pressing the bearing out of the housing, never support the housing on its peripheral lugs, as they will break under the loads imparted by the press. Always support the housing on its outer circumference ensuring the maximum arc of that circumference is supported.
11. Support the outer circumference of the bearing housing on press bars, then press the bearing through the housing.
Pressing out the bearing
Inspection
1. Examine all gears, bearings and bushes and thrust washers for damage, distortion, chipped teeth and wear beyond the service limits. Replace all defective components and always use new circlips to assemble the shaft.
2. Thoroughly clean the bearing housing and inspect for damage, scoring and cracks. Replace the housing if necessary
Assembly
Note: Lubricate each gear, thrust washer and bush with clean engine oil during assembly.
Note: The circlips used on the input shaft have a flat side and an angled side. Illustrations throughout the assembly text indicate which orientation of each circlip is correct.
Warning!
- When using a press, always wear overalls, eye face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body.
- Never wear loose clothing, which could become trapped in the press and cause crushing injury to the hand, arms or other parts of the anatomy.
Caution! Bushes with oil holes must always be MISALIGNED with the corresponding oil holes in the output shaft. Reduced oil pressure and gear lubrication may result from alignment of the oil holes, which would cause premature wear of engine and transmission components.
Caution! Removing the input shaft bearing from the shaft and its housing will damage the bearing and snap ring. Never re-use removed bearings or snap rings as use of damaged or weakened components could lead to engine and transmission damage. Also, check for damage to the housing itself.
1. Position a new bearing to the housing.
Caution! Press only on the bearing outer race to prevent bearing damage.
2. Support the housing on press bars as shown below and press the bearing fully into the housing in the direction of the arrow.
1. Bearing housing; 2. Bearing
3. Retain the bearing with a new snap ring.
Caution! Press only on the bearing inner race to prevent bearing damage.
4. Locate the bearing and housing to the input shaft. Support the shaft on the press bed and press the bearing onto the shaft.
1. Shaft; 2. Bearing/housing; 3. Press bars
5. Working now on the opposite end to the bearing, slide on the thrust washer (6).
6. Fit the bush (9).
7. Fit the Belleville washers (7) over the bush, arranging them as shown below.
1. Thrust washer; 2. Belleville washers; 3. Bush
8. Fit fifth gear (8) and the fifth gear thrust washer (10).
9. Retain the assembly with a new circlip (11), orientating the circlip as shown below.
1. Fifth gear; 2. Fifth gear thrust washer; 3. Circlip
10. Fit the third/fourth gear (12) to the shaft.
11. Retain third/fourth gear with a new circlip (13), orientating the circlip as shown below.
1. Third/fourth gear; 2. Circlip
12. Slide on second gear (14).
13. Retain second gear with a new circlip (13), orientating the circlip as shown below.
1. Second gear; 2. Circlip