INPUT SHAFT REASSEMBLY

PROCEDURE


  1. INSTALL FRONT INPUT SHAFT BEARING


    1. A01VFXT

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

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    1. A01VHQ5

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

  3. INSTALL 3RD GEAR


    1. A01VLVR

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

  4. INSTALL NO. 3 SYNCHRONIZER RING


    1. A01VG24

      Coat the No. 3 synchronizer ring with manual transaxle oil and install it onto the 3rd gear.

  5. INSTALL NO. 2 TRANSMISSION CLUTCH HUB


    1. Coat the No. 2 transmission clutch hub with manual transaxle oil.

    2. A01VGS2

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

      Note

      Position the No. 2 transmission clutch hub correctly as shown in the illustration.

    3. A01VGVZE05

      Using SST and a press, install the No. 2 transmission clutch hub onto 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 snap ring that will allow minimal axial play.

      Standard clearance
      0.1 mm (0.00394 in.) or less
      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 the new No. 2 clutch hub setting shaft snap ring.

      Note


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

      • Do not damage the journal surface of the 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 manual transaxle oil.

    2. A01VFVOE06
      Text in Illustration
      *a Align

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

      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 onto the No. 2 clutch hub setting shaft snap ring.

  10. INSTALL 4TH GEAR NEEDLE ROLLER BEARING


    1. A01VF2E

      Coat the 4th gear needle roller bearing and 4th gear bearing spacer with manual transaxle oil and install them onto the No. 2 transmission clutch hub.

  11. INSTALL OUTER 2ND SYNCHRONIZER RING


    1. A01VGG7

      Coat the outer 2nd synchronizer ring with manual transaxle oil and install it onto 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 manual transaxle oil and install it onto the input shaft.

      Note

      Install the 4th gear 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 manual transaxle oil and install it onto the input shaft.

  14. INSTALL INNER 5TH GEAR BEARING RACE


    1. A01VGHL

      Coat the inner 5th gear bearing race with manual transaxle oil and install it onto 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 manual transaxle oil and install them onto the input shaft.

  16. INSTALL 5TH GEAR


    1. A01VH3K

      Coat the 5th gear with manual transaxle oil and install it onto the input shaft.

      Note

      Install the 5th gear as shown in the illustration.

  17. INSTALL NO. 5 SYNCHRONIZER RING


    1. A01VH6C

      Coat the No. 5 synchronizer ring with manual transaxle oil and install it onto the 5th gear.

  18. INSTALL NO. 3 TRANSMISSION CLUTCH HUB


    1. Coat the No. 3 transmission clutch hub with manual transaxle oil.

    2. A01VJJG

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

      Note

      Position the No. 3 transmission clutch hub correctly as shown in the illustration.

    3. A01VHXSE06

      Using SST and a press, install the No. 3 transmission clutch hub onto 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 manual transaxle oil.

    2. A01VIJP

      Install the No. 3 transmission hub sleeve onto 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 LOCK BALL


    1. A01VLU7

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

  22. INSTALL INNER 6TH GEAR BEARING RACE


    1. A01VM7A

      Coat the inner 6th gear bearing race with manual transaxle oil and install it onto 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 manual transaxle oil and install them onto the input shaft.

  24. INSTALL NO. 5 SYNCHRONIZER RING


    1. A01VLV1

      Coat the No. 5 synchronizer ring with manual transaxle oil and install it onto 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.

  25. INSTALL 6TH GEAR SUB-ASSEMBLY


    1. A01VERD

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

      Note

      Install the 6th gear sub-assembly as shown in the illustration.

  26. INSTALL REAR INPUT SHAFT RADIAL BALL BEARING


    1. A01VF0EE05

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

      SST
      09527-21011
      09608-04031

  27. 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
      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 the new rear input shaft bearing shaft snap ring.

      Note


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

      • Do not damage the journal surface of the 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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