Input Shaft

Fig 1: Input Shaft

Courtesy of CHRYSLER LLC

Before disassembly of the input shaft (1), it is necessary to check the synchronizer stop ring gap. Use a feeler gauge to measure the gaps between the stop rings (2, 5, and 8) and the speed gears. The correct gaps are listed below: See Fig 1.

1. 3rd - 0.73-1.53 mm (0.029-0.060 in)
2. 4th - 0.77-1.57 mm (0.030-0.062 in).
3. 5th - 0.73-1.53 mm (0.029-0.060 in)
4. Reverse Brake - 0.505-1.74 mm (0.020-0.068 in.)

The reverse brake measurement is taken between the stop ring and case.

If a stop ring gap does not fall within the specifications, it must be inspected for wear and replaced. If the 1st or 2nd synchronizer stop ring is worn beyond specifications, the complete output shaft assembly must be replaced.

The input shaft incorporates the 3rd, 4th, and 5th speed gears and synchronizers on the assembly.

Fig 2: Removing/Installing 5th Gear Synchronizer Snap Ring

Courtesy of CHRYSLER LLC

1. Install Bearing Splitter 1130 (3) behind 5th speed gear. Remove snap ring (4) at 5th synchronizer hub on input shaft (2). See Fig 2.
   Fig 3: Removing Synchronizer Using Shop Press

   Courtesy of CHRYSLER LLC

   1 - PRESS RAM

   2 - INPUT SHAFT

   3 - BEARING SPLITTER

   4 - SYNCHRONIZER ASSEMBLY

2. Remove synchronizer (4) and gear using shop press (1). See Fig 3.
   Fig 4: Removing/Installing Caged Needle Bearing

   Courtesy of CHRYSLER LLC

   1 - INPUT SHAFT

   2 - CAGED NEEDLE BEARING

3. Remove caged needle bearing (2). See Fig 4.
   Fig 5: Split Thrust Washer Ring

   Courtesy of CHRYSLER LLC

   1 - SPLIT THRUST WASHER RING

   2 - INPUT SHAFT

4. Remove 4-5 gears split thrust washer ring (1). See Fig 5.
   Fig 6: Removing/Installing Split Thrust Washer

   Courtesy of CHRYSLER LLC

   1 - INPUT SHAFT

   2 - SPLIT THRUST WASHER

5. Remove split thrust washer (2). See Fig 6.
   Fig 7: Split Thrust Washer Separation Pin

   Courtesy of CHRYSLER LLC

   1 - SEPARATION PIN

   2 - INPUT SHAFT

   3 - PLIERS

6. Remove split thrust washer separation pin (1). See Fig 7.
   Fig 8: Removing 4th Gear

   Courtesy of CHRYSLER LLC

   1 - INPUT SHAFT

   2 - 4TH GEAR

7. Remove 4th gear (2). See Fig 8.
   Fig 9: Removing Caged Needle Bearing

   Courtesy of CHRYSLER LLC

   1 - INPUT SHAFT

   2 - CAGED NEEDLE BEARING

8. Remove 4th gear caged needle bearing (2). See Fig 9. Check the caged needle bearing (2) for a broken retention spring.
   Fig 10: 3-4 Synchronizer Hub Snap Ring

   Courtesy of CHRYSLER LLC

   1 - SNAP RING PLIERS

   2 - SYNCHRO SNAP RING

   3 - SYNCHRONIZER ASSEMBLY

9. Remove blocking ring. Remove 3-4 synchronizer hub retaining snap ring (3). See Fig 10.
   Fig 11: Removing 3rd Gear

   Courtesy of CHRYSLER LLC

   1 - PRESS RAM

   2 - INPUT SHAFT

   3 - 3RD GEAR

   4 - SYNCHRONIZER ASSEMBLY

10. Install input shaft in shop press (1). See Fig 11. Using Bearing Splitter 1130, remove 3-4 synchronizer and 3rd gear (3).
    Fig 12: 3rd Gear Caged Needle Bearing

    Courtesy of CHRYSLER LLC

    1 - INPUT SHAFT

    2 - 3RD GEAR CAGED NEEDLE BEARING

11. Remove 3rd gear caged needle bearing (2). See Fig 12. Inspect needle bearing for a broken retention spring.
12. Inspect the input shaft for worn or damaged bearing races or chipped gear teeth. Replace as necessary.