INPUT SHAFT REASSEMBLY

PROCEDURE


  1. INSTALL FRONT INPUT SHAFT BEARING


    1. A01VJ77E04

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

      SST
      09515-10010

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    1. A01VFRP

      Coat the 3rd gear needle roller bearing with gear oil, and install it onto the input shaft.

  3. INSTALL 3RD GEAR


    1. A01VJAZ

      Coat the 3rd gear with gear oil, and install it onto the input shaft.

  4. INSTALL 3RD GEAR SYNCHRONIZER RING


    1. A01VHM2

      Coat the 3rd gear synchronizer ring with gear oil, and install it onto the 3rd gear.

  5. INSTALL NO. 2 TRANSMISSION CLUTCH HUB


    1. A01VEKU

      Install the No. 2 transmission hub sleeve to the No. 2 transmission clutch hub, and then install the 3 No. 2 shifting keys and 2 shifting key springs.

      Note

      Assemble the No. 2 transmission hub sleeve and No. 2 transmission clutch hub in the correct orientations shown in the illustration.

    2. A01VFYQE04

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

      SST
      09506-35010

      Note


      • Install the No. 2 transmission clutch hub in the correct orientation shown in the illustration.

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

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


    1. A01VIF3E06
      Text in Illustration
      *a Alignment Mark

      Select a snap ring that allows the minimum axial play.

      Standard clearance
      0.1 mm (0.00393 in.) or less.
      Snap Ring Thickness
      Part No. Mark

      Thickness

      mm (in.)
      90520-32014 A 2.280 (0.0898)
      90520-32015 B 2.340 (0.0921)
      90520-32016 C 2.400 (0.0945)
      90520-32017 D 2.460 (0.0969)
      90520-32018 E 2.520 (0.0992)
      90520-32019 F 2.580 (0.1016)
    2. A01VIE7

      Using a snap ring expander, install the new snap ring onto the input shaft.

      Note

      Do not damage the journal surface of the input shaft.

    3. Inspect the 3rd gear thrust clearance and radial clearance Click here.

      If either clearance is more than the maximum, check the installation condition of the No. 2 transmission clutch hub and repeat the procedure to select a No. 2 clutch hub setting shaft snap ring.

  7. INSTALL 4TH GEAR SYNCHRONIZER RING


    1. A01VLL3

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

  8. INSTALL 4TH GEAR BEARING SPACER


    1. A01VFPW

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

  9. INSTALL 4TH GEAR NEEDLE ROLLER BEARING


    1. A01VDJB

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

  10. INSTALL 4TH GEAR


    1. A01VFRW

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

  11. INSTALL 5TH GEAR THRUST WASHER BALL


    1. A01VIJR

      Install the 5th gear thrust washer ball to the input shaft.

  12. INSTALL 5TH GEAR THRUST WASHER


    1. A01VHSH

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

  13. INSTALL 5TH GEAR SHAFT SNAP RING


    1. A01VFFBE05
      Text in Illustration
      *a Alignment Mark

      Using the table below, select a new 5th gear shaft snap ring that alignment makes the thrust clearance of the 5th gear thrust washer less than 0.1 mm (0.00393 in.).

      Plate Shim Thickness
      Part No. Mark

      Thickness

      mm (in.)
      09520-29049 1 2.280 (0.0898)
      09520-29050 2 2.340 (0.0921)
      90520-29052 3 2.400 (0.0945)
      90520-29053 4 2.460 (0.0969)
      90520-29054 5 2.520 (0.0992)
      90520-29055 6 2.580 (0.1016)
    2. A01VG45

      Using a snap ring expander, install the new 5th gear shaft snap ring to the input shaft.

      Note

      Do not damage the journal surface of the input shaft.

    3. Inspect the 4th gear thrust clearance and radial clearance Click here.

      If either clearance is more than the maximum, repeat the procedure to select a 5th gear shaft snap ring.

  14. INSTALL 5TH GEAR BEARING SPACER


    1. A01VE3M

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

  15. INSTALL 5TH GEAR NEEDLE ROLLER BEARING


    1. A01VL1J

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

  16. INSTALL 5TH GEAR


    1. A01VEIT

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

  17. INSTALL 5TH GEAR SYNCHRONIZER RING


    1. A01VEGM

      Coat the 5th gear synchronizer ring with gear oil and install it to the 5th gear.

  18. INSTALL NO. 3 TRANSMISSION CLUTCH HUB


    1. A01VM2R

      Install the No. 3 transmission hub sleeve to the No. 3 transmission clutch hub, and then install the 3 No. 3 shifting keys and 2 No. 1 shifting key springs.

      Note

      Assemble the No. 3 transmission hub sleeve, 3 No. 3 shifting keys and No. 3 transmission clutch hub in the correct orientations shown in the illustration.

    2. Install the No. 3 transmission hub sleeve to the input shaft, and then align the 5th gear synchronizer ring slots with No. 3 shifting keys.

    3. A01VIIVE01

      Using SST and a press, install the No. 3 transmission clutch hub set to the input shaft.

      SST
      09515-10010

      Note

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

  19. INSTALL REAR INPUT SHAFT RADIAL BALL BEARING


    1. A01VI67E01

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

      SST
      09515-10010

    2. Inspect the 5th gear thrust clearance and radial clearance Click here.