INPUT SHAFT REASSEMBLY

PROCEDURE


  1. INSTALL FRONT INPUT SHAFT BEARING


    1. A01VFXT

      Using a press, install the front input shaft bearing to the input shaft.

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    1. A01VHQ5

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

  3. INSTALL 3RD GEAR


    1. A01VLVR

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

  4. INSTALL NO. 3 SYNCHRONIZER RING


    1. A01VG24

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

  5. INSTALL NO. 2 TRANSMISSION CLUTCH HUB


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

    2. A01VGS2

      Install the No. 2 transmission clutch hub to the input shaft.

      Note

      Be sure to install the No. 2 transmission clutch hub in the correct direction as shown in the illustration.

    3. A01VGVZE11

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

      SST
      09527-21011
      09316-60011   ( 09316-00011 )

      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 No. 2 clutch hub setting shaft snap ring that will allow minimal axial play.

      Standard clearance
      0.1 mm (0.00394 in.) or less
      No. 2 Clutch Hub Setting Shaft Snap Ring Thickness
      Part No. Mark

      Thickness

      mm (in.)
      90520-35034 0 2.27 (0.0894)
      90520-35035 1 2.32 (0.0913)
      90520-35036 2 2.37 (0.0933)
      90520-35037 3 2.42 (0.0953)
      90520-35038 4 2.47 (0.0972)
      90520-35039 5 2.52 (0.0992)
      90520-35040 6 2.57 (0.1012)
      90520-35041 7 2.62 (0.1031)
    2. A01VGRO

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

      Note


      • Be sure to properly install the No. 2 clutch hub setting shaft snap ring because it easily expands.

      • Do not damage the journal surface of the No. 2 clutch hub setting shaft snap ring.

  7. INSTALL NO. 2 SYNCHROMESH SHIFTING KEY


    1. A01VG15

      Install the 3 No. 2 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. A01VFVOE05
      Text in Illustration
      *a Align

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

      Note

      When installing the No. 2 transmission hub sleeve, align the protrusion of the No. 2 transmission hub sleeve with the cutout of the No. 2 transmission clutch hub.

  9. INSTALL 4TH GEAR BEARING SPACER


    1. A01VE8J

      Install the 4th gear bearing spacer to the No. 2 transmission clutch hub.

  10. INSTALL 4TH GEAR NEEDLE ROLLER BEARING


    1. A01VF2E

      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.

  11. INSTALL OUTER 2ND SYNCHRONIZER RING


    1. A01VGG7

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

      Note

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

  12. INSTALL 4TH GEAR


    1. A01VI2Q

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

      Note

      Be sure to install the 4th gear in the correct direction as shown in the illustration.

  13. INSTALL INNER 5TH GEAR BEARING RACE LOCK BALL


    1. A01VHFL

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

  14. INSTALL INNER 5TH GEAR BEARING RACE


    1. A01VGHL

      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.

  15. INSTALL 5TH GEAR NEEDLE ROLLER BEARING


    1. A01VJCL

      Coat 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.

  16. INSTALL 5TH GEAR


    1. A01VH3K

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

      Note

      Be sure to install the 5th gear in the correct direction as shown in the illustration.

  17. INSTALL NO. 5 SYNCHRONIZER RING (FOR 5TH GEAR)


    1. A01VH6C

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

  18. INSTALL NO. 3 TRANSMISSION CLUTCH HUB


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

    2. A01VIOY

      Install the No. 3 transmission clutch hub to the input shaft.

      Note

      Be sure to install the No. 3 transmission clutch hub in the correct direction as shown in the illustration.

    3. A01VHXSE07

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

      SST
      09309-37010
      09527-21011

      Note

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

  19. INSTALL NO. 3 SYNCHROMESH SHIFTING KEY


    1. A01VHTB

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

  20. INSTALL NO. 3 TRANSMISSION HUB SLEEVE


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

    2. A01VIJP

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

      Note

      Be sure to install the No. 3 transmission hub sleeve in the correct direction as shown in the illustration.

  21. INSTALL INNER 6TH GEAR BEARING RACE LOCK BALL


    1. A01VLU7

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

  22. INSTALL INNER 6TH GEAR BEARING RACE


    1. A01VM7A

      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.

  23. INSTALL 6TH GEAR NEEDLE ROLLER BEARING


    1. A01VEPU

      Coat 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.

  24. INSTALL NO. 5 SYNCHRONIZER RING (FOR 6TH GEAR)


    1. A01VLV1

      Coat the No. 5 synchronizer ring (for 6th gear) with gear oil and install it to the No. 3 transmission clutch hub.

      Note

      When installing the No. 5 synchronizer ring (for 6th gear), align the protrusion of the No. 5 synchronizer ring (for 6th gear) with the cutout of the No. 3 transmission clutch hub.

  25. INSTALL 6TH GEAR SUB-ASSEMBLY


    1. A01VERD

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

      Note

      Be sure to install the 6th gear sub-assembly in the correct direction as shown in the illustration.

  26. INSTALL REAR INPUT SHAFT RADIAL BALL BEARING


    1. A01VF0EE09

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

      SST
      09527-21011
      09608-04031

  27. INSTALL REAR INPUT SHAFT BEARING SHAFT SNAP RING


    1. Select a new rear input shaft bearing shaft snap ring that will allow minimal axial play.

      Standard clearance
      0.1 mm (0.00394 in.) or less
      Rear Input Shaft Bearing Shaft Snap Ring Thickness
      Part No. Mark

      Thickness

      mm (in.)
      90520-25059 A 1.65 (0.0650)
      90520-25062 B 1.70 (0.0669)
      90520-25063 C 1.75 (0.0689)
      90520-25064 D 1.80 (0.0709)
      90520-25065 E 1.85 (0.0728)
      90520-25066 F 1.90 (0.0748)
      90520-25067 G 1.95 (0.0768)
      90520-25068 H 2.00 (0.0787)
      90520-25069 J 2.05 (0.0807)
      90520-25070 K 2.10 (0.0827)
      90520-25071 L 2.15 (0.0846)
      90520-25072 M 2.20 (0.0866)
      90520-25074 N 2.25 (0.0886)
      90520-25075 P 2.30 (0.0906)
    2. A01VK5X

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

      Note


      • Be sure to properly install the rear input shaft bearing shaft snap ring because it easily expands.

      • Do not damage the journal surface of the rear input shaft bearing shaft snap ring.

  28. INSPECT 3RD GEAR RADIAL CLEARANCE

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  29. INSPECT 4TH GEAR RADIAL CLEARANCE

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  30. INSPECT 5TH GEAR RADIAL CLEARANCE

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  31. INSPECT 6TH GEAR RADIAL CLEARANCE

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  32. INSPECT 3RD GEAR THRUST CLEARANCE

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  33. INSPECT 4TH GEAR THRUST CLEARANCE

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  34. INSPECT 5TH GEAR THRUST CLEARANCE

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  35. INSPECT 6TH GEAR THRUST CLEARANCE

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