INPUT SHAFT REASSEMBLY

PROCEDURE

  1. INSTALL FRONT INPUT SHAFT BEARING

    1. C200197N01

      Using SST and a press, press the front input shaft bearing onto the input shaft.

      09950-60010

      09951-00180

      09951-00350

      09952-06010

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING

    1. C200198

      Coat the 2 pieces of the 3rd gear needle roller bearing with gear oil and install them to the input shaft.

  3. INSTALL 3RD GEAR

    1. C200199

      Coat the 3rd gear sub-assembly with gear oil and install it to the input shaft.

  4. INSTALL NO. 3 SYNCHRONIZER RING

    1. C200200

      Coat the No. 3 synchronizer ring with gear oil and install it to the 3rd gear sub-assembly.

  5. INSTALL NO. 2 TRANSMISSION CLUTCH HUB

    1. Coat the No. 2 transmission clutch hub with gear oil.

    2. C278712N01

      Using SST and a press, press the No. 2 transmission clutch hub to the input shaft.

      09316-60011

      09316-00011

      09527-21011

      Note:

      When installing the No. 2 transmission clutch hub, align the protrusion of the No. 3 synchronizer ring with the cutout of the No. 2 transmission clutch hub.

  6. INSTALL NO. 2 CLUTCH HUB SETTING SHAFT SNAP RING

    1. Select a new snap ring that will allow minimal axial play.

      Standard clearance

      0.1 mm (0.00394 in.) or less

      Standard Snap Ring Thickness

      Mark

      Specified Condition

      Mark

      Specified Condition

      0

      2.30 mm (0.0905 in.)

      3

      2.48 mm (0.0976 in.)

      1

      2.36 mm (0.0929 in.)

      4

      2.54 mm (0.0999 in.)

      2

      2.42 mm (0.0952 in.)

      5

      2.60 mm (0.1023 in.)
    2. C200202

      Using a snap ring expander, install the No. 2 clutch hub setting shaft snap ring.

      Note:

      • Be sure to properly install the snap ring as it easily expands.

      • Do not damage the journal surface of the snap ring.

  7. INSTALL SYNCHROMESH SHIFTING KEY

    1. C200203

      Install the 3 synchromesh shifting keys to the No. 2 transmission clutch hub.

  8. INSTALL NO. 2 TRANSMISSION HUB SLEEVE

    1. Coat the No. 2 transmission hub sleeve with gear oil.

    2. Install the No. 2 transmission hub sleeve to the No. 2 transmission clutch hub.

  9. INSTALL 4TH GEAR BEARING SPACER

    1. C200205

      Install the 4th gear bearing spacer to the input shaft.

  10. INSTALL 4TH GEAR SYNCHRONIZER RING

    1. C284642

      Coat the No. 4 synchronizer ring with gear oil and install it to the No. 2 transmission clutch hub.

      Note:

      When installing the No. 4 synchronizer ring, align the protrusion of the No. 4 synchronizer ring with the cutout of the No. 2 transmission clutch hub.

  11. INSTALL 4TH GEAR

    1. C206855

      Coat the 4th gear needle roller bearing and 4th gear bearing spacer with gear oil and install the 4th gear needle roller bearing to the input shaft.

      Tip:

      The 4th gear sub-assembly and 4th gear needle roller bearing are supplied as a set. When replacing the 4th gear sub-assembly or 4th gear needle roller bearing, replace them together as a set.

    2. C200209

      Coat the 4th gear sub-assembly with gear oil and install it to the input shaft.

      Note:

      Install the 4th gear sub-assembly as shown in the illustration.

  12. INSTALL INNER 5TH GEAR BEARING RACE LOCK BALL

    1. C200210

      Coat the inner 5th gear bearing race lock ball with gear oil and install it to the input shaft.

  13. INSTALL INNER 5TH GEAR BEARING RACE

    1. C200211

      Coat the inner 5th gear bearing race with gear oil and install it to the input shaft.

      Note:

      Align the groove of the inner 5th gear bearing race with the ball.

  14. INSTALL 5TH GEAR NEEDLE ROLLER BEARING

    1. C200212

      Coat the 2 pieces of the 5th gear needle roller bearing and inner 5th gear bearing race with gear oil and install the 5th gear needle roller bearing to the input shaft.

  15. INSTALL 5TH GEAR

    1. C200213

      Coat the 5th gear with gear oil and install it to the input shaft.

      Note:

      Install the 5th gear as shown in the illustration.

  16. INSTALL NO. 5 SYNCHRONIZER RING

    1. C200214

      Coat the No. 5 synchronizer ring with gear oil and install it to the 5th gear.

  17. INSTALL NO. 3 TRANSMISSION CLUTCH HUB

    1. Coat the No. 3 transmission clutch hub with gear oil.

    2. C200216N01

      Using SST and a press, press the No. 3 transmission clutch hub onto the input shaft.

      09309-37010

      09527-21011

      Note:

      When installing the No. 3 transmission clutch hub, align the protrusion of the No. 5 synchronizer ring with the cutout of the No. 3 transmission clutch hub.

  18. INSTALL SYNCHROMESH SHIFTING KEY

    1. C200218

      Install the 3 synchromesh shifting keys to the No. 3 transmission clutch hub.

  19. INSTALL INNER 6TH GEAR BEARING RACE LOCK BALL

    1. C200217

      Coat the inner 6th gear bearing race lock ball with gear oil and install it to the input shaft.

  20. INSTALL NO. 3 TRANSMISSION HUB SLEEVE

    1. Coat the No. 3 transmission hub sleeve with gear oil.

    2. C200219

      Install the No. 3 transmission hub sleeve to the No. 3 transmission clutch hub.

      Note:

      Install the No. 3 transmission hub sleeve as shown in the illustration.

  21. INSTALL INNER 6TH GEAR BEARING RACE

    1. C200220

      Coat the inner 6th gear bearing race with gear oil and install it to the input shaft.

      Note:

      Align the groove of the inner 6th gear bearing race with the ball.

  22. INSTALL 6TH GEAR NEEDLE ROLLER BEARING

    1. C200221

      Coat the 2 pieces of the 6th gear needle roller bearing and inner 6th gear bearing race with gear oil and install the 6th gear needle roller bearing to the input shaft.

  23. INSTALL NO. 5 SYNCHRONIZER RING

    1. C200222

      Coat the No. 5 synchronizer ring with gear oil and install it to the No. 3 transmission clutch hub.

      Note:

      When installing the No. 5 synchronizer ring, align the protrusion of the No. 5 synchronizer ring with the cutout of the No. 3 transmission clutch hub.

  24. INSTALL 6TH GEAR SUB-ASSEMBLY

    1. C200223

      Coat the 6th gear with gear oil and install it to the input shaft.

      Note:

      Install the 6th gear as shown in the illustration.

  25. INSTALL REAR INPUT SHAFT RADIAL BALL BEARING

    1. C278713N01

      Using SST and a press, press the rear input shaft radial ball bearing onto the input shaft.

      09527-21011

      09608-04031

  26. INSTALL REAR INPUT SHAFT BEARING SHAFT SNAP RING

    1. Select a new snap ring that will allow minimal axial play.

      Standard clearance

      0.1 mm (0.00394 in.) or less

      Standard Snap Ring Thickness

      Mark

      Specified Condition

      Mark

      Specified Condition

      0

      1.90 mm (0.0748 in.)

      6

      2.26 mm (0.0889 in.)

      1

      1.96 mm (0.0771 in.)

      7

      2.32 mm (0.0913 in.)

      2

      2.02 mm (0.0795 in.)

      8

      2.38 mm (0.0937 in.)

      3

      2.08 mm (0.0818 in.)

      9

      2.44 mm (0.0960 in.)

      4

      2.14 mm (0.0842 in.)

      A

      2.50 mm (0.0984 in.)

      5

      2.20 mm (0.0866 in.)

      -

      -
    2. C199078

      Using a snap ring expander, install the rear input shaft bearing shaft snap ring.

      Note:

      • Be sure to properly install the snap ring as it easily expands.

      • Do not damage the journal surface of the snap ring.

  27. INSPECT 3RD GEAR RADIAL CLEARANCE

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  28. INSPECT 4TH GEAR RADIAL CLEARANCE

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  29. INSPECT 5TH GEAR RADIAL CLEARANCE

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  30. INSPECT 6TH GEAR RADIAL CLEARANCE

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  31. INSPECT 3RD GEAR THRUST CLEARANCE

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  32. INSPECT 4TH GEAR THRUST CLEARANCE

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  33. INSPECT 5TH GEAR THRUST CLEARANCE

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  34. INSPECT 6TH GEAR THRUST CLEARANCE

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