INPUT SHAFT DISASSEMBLY


  1. INSPECT 3RD GEAR THRUST CLEARANCE


    1. A0137WVE01

      Using a feeler gauge, measure the 3rd gear thrust clearance.

      Standard clearance
      0.10 to 0.35 mm (0.00394 to 0.0137 in.)
      Maximum clearance
      0.35 mm (0.0137 in.)

      If the clearance is more than the maximum, replace the No. 2 transmission clutch hub, 3rd gear or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  2. INSPECT 5TH GEAR THRUST CLEARANCE


    1. A0137MUE01

      Using a dial indicator, measure the 5th gear thrust clearance.

      Standard clearance
      0.10 to 0.50 mm (0.00394 to 0.0196 in.)
      Maximum clearance
      0.50 mm (0.0196 in.)

      If the clearance is more than the maximum, replace the No. 3 transmission clutch hub, 5th gear or 5th gear thrust washer. Replace the part or parts determined to be the most likely cause of the problem.

  3. INSPECT 3RD GEAR RADIAL CLEARANCE


    1. A0138MVE01

      Using a dial indicator, measure the 3rd gear radial clearance.

      Standard clearance
      0.015 to 0.058 mm (0.000591 to 0.00228 in.)
      Maximum clearance
      0.058 mm (0.00228 in.)

      If the clearance is more than the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  4. INSPECT 4TH GEAR RADIAL CLEARANCE


    1. A0137SEE01

      Using a dial indicator, measure the 4th gear radial clearance.

      Standard clearance
      0.015 to 0.058 mm (0.000591 to 0.00228 in.)
      Maximum clearance
      0.058 mm (0.00228 in.)

      If the clearance is more than the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  5. INSPECT 5TH GEAR RADIAL CLEARANCE


    1. A0137C1E01

      Using a dial indicator, measure the 5th gear radial clearance.

      Standard clearance
      0.015 to 0.058 mm (0.000591 to 0.00228 in.)
      Maximum clearance
      0.058 mm (0.00228 in.)

      If the clearance is more than the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  6. REMOVE 5TH GEAR


    1. A0137DYE02

      Using SST and a press, remove the input shaft rear radial ball bearing, No. 3 transmission clutch hub set, 5th gear synchronizer ring and the 5th gear from the input shaft.

      SST
      09950-00020
      09612-24014   ( 09612-10061 )

      Note


      • Do not excessively tighten SST.

      • Support the input shaft by hand to prevent it from dropping.

      Tech Tips

      Set the claw of SST between the 4th gear and the 5th gear as shown in the illustration.

  7. REMOVE NO. 3 TRANSMISSION CLUTCH HUB


    1. A0135VRE01

      Remove the 2 No. 3 shifting key springs from the No. 3 transmission clutch hub.

    2. Remove the No. 3 transmission hub sleeve from the No. 3 transmission clutch hub.

    3. Remove the 3 No. 3 shifting keys from the No. 3 transmission clutch hub.

  8. REMOVE 5TH GEAR NEEDLE ROLLER BEARING


    1. A0136QN

      Remove the 5th gear needle roller bearing from the input shaft.

  9. REMOVE 5TH GEAR BEARING SPACER


    1. A0138A1E01

      Remove the 5th gear bearing spacer from the input shaft.

  10. INSPECT 4TH GEAR THRUST CLEARANCE


    1. A0138IVE01

      Using a dial indicator, measure the 4th gear thrust clearance.

      Standard clearance
      0.10 to 0.55 mm (0.00394 to 0.0216 in.)
      Maximum clearance
      0.55 mm (0.0216 in.)

      If the clearance is more than the maximum, replace the No. 2 transmission clutch hub, 4th gear or 5th gear thrust washer. Replace the part or parts determined to be the most likely cause of the problem.

  11. REMOVE 5TH GEAR SHAFT SNAP RING


    1. A0136AKE01

      Using a snap ring expander, remove the 5th gear shaft snap ring from the input shaft.

      Note

      Do not damage the journal surface of the input shaft.

  12. REMOVE 5TH GEAR THRUST WASHER


    1. A0136F5E01

      Remove the 5th gear thrust washer from the input shaft.

  13. REMOVE 5TH GEAR THRUST WASHER BALL


    1. A01365WE01

      Using a magnet hand, remove the 5th gear thrust washer ball from the input shaft.

  14. REMOVE 4TH GEAR


    1. A0138HKE01

      Remove the 4th gear from the input shaft.

  15. REMOVE 4TH GEAR NEEDLE ROLLER BEARING


    1. A0138JT

      Remove the 4th gear needle roller bearing from the input shaft.

  16. REMOVE 4TH GEAR BEARING SPACER


    1. A0137ZYE01

      Remove the 4th gear bearing spacer from the input shaft.

  17. REMOVE 4TH GEAR SYNCHRONIZER RING


    1. A0137LXE01

      Remove the 4th gear synchronizer ring from the No. 2 transmission clutch hub.

  18. REMOVE NO. 2 CLUTCH HUB SETTING SHAFT SNAP RING


    1. A01369CE01

      Using a snap ring expander, remove the No. 2 clutch hub setting shaft snap ring from the input shaft.

      Note

      Do not damage the journal surface of the input shaft.

  19. REMOVE 3RD GEAR


    1. A0138WKE04

      Using SST and a press, remove the No. 2 transmission clutch hub set, 3rd gear synchronizer ring and the 3rd gear from the input shaft.

      SST
      09950-00020

      Note


      • Do not excessively tighten SST.

      • Support the input shaft by hand to prevent it from dropping.

  20. REMOVE NO. 2 TRANSMISSION CLUTCH HUB


    1. A0136P7E01

      Remove the 2 No. 2 shifting key springs from the No. 2 transmission clutch hub.

    2. Remove the No. 2 transmission hub sleeve from the No. 2 transmission clutch hub.

    3. Remove the 3 No. 2 shifting keys from the No. 2 transmission clutch hub.

  21. REMOVE 3RD GEAR NEEDLE ROLLER BEARING


    1. A01375B

      Remove the 3rd gear needle roller bearing from the input shaft.

  22. REMOVE INPUT SHAFT FRONT BEARING


    1. A01361ME05

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

      SST
      09950-00020

      Note

      Support the input shaft by hand to prevent it from dropping.