INPUT SHAFT REASSEMBLY


  1. INSTALL INPUT SHAFT FRONT BEARING

    A0138A6E01

    1. 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

    A01360C

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

  3. INSTALL 3RD GEAR

    A0136X3

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

  4. INSTALL 3RD GEAR SYNCHRONIZER RING

    A0138E8

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

  5. INSTALL TRANSMISSION CLUTCH HUB NO.2

    A0136P7

    1. Install 3 shifting keys No. 2, 2 shifting key springs and transmission hub sleeve No. 2 onto clutch hub No. 2.

      Note

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

    2. A0138EME01

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

      SST
      09506-35010

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

    A0136IDE01

    1. Select a snap ring that allows the minimum axial play.

      Standard clearance
      0.1mm (0.0039 in.) or less
      Mark

      Thickness

      mm (in.)

      		 Mark

      Thickness

      mm (in.)
      A 2.28 (0.0898) D 2.46 (0.0969)
      B 2.34 (0.0921) E 2.52 (0.0992)
      C 2.40 (0.0945) F 2.58 (0.1016)
    2. A01369C

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

      Tech Tips

      Do not damage the journal surface of the input shaft.

  7. INSPECT 3RD GEAR THRUST CLEARANCE

    A0137QR

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

      Standard clearance
      0.10 to 0.35 mm (0.0039 to 0.0138 in.)
      Maximum clearance
      0.35 mm (0.0138 in.)

  8. INSPECT 3RD GEAR RADIAL CLEARANCE

    A01378F

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

      Standard clearance
      0.015 to 0.058 mm (0.0006 to 0.0023 in.)

      If the clearance exceeds the maximum, replace the 3rd gear needle roller bearing or the shaft.

  9. INSTALL 4TH GEAR SYNCHRONIZER RING

    A0137LX

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

  10. INSTALL 4TH GEAR BEARING SPACER

    A0137ZY

    1. Coat the 4th gear bearing spacer with gear oil, and install it onto the input shaft.

  11. INSTALL 4TH GEAR NEEDLE ROLLER BEARING

    A0136PL

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

  12. INSTALL 4TH GEAR

    A0138HK

    1. Coat the 4th gear with gear oil, and install it onto the input shaft.

  13. INSTALL 5TH GEAR THRUST WASHER BALL

    A0135ZC

    1. Install the 5th gear thrust washer ball onto the input shaft.

  14. INSTALL 5TH GEAR THRUST WASHER

    A0136F5

    1. Coat the 5th gear thrust washer with gear oil, and install it onto the input shaft.

  15. INSTALL 5TH GEAR SHAFT SNAP RING


    1. A0138BSE01

      Select a snap ring, using the table below, that makes the thrust clearance of the 5th gear thrust washer less than 0.1 mm (0.0039 in.).

      Mark

      Thickness

      mm (in.)

      		 Mark

      Thickness

      mm (in.)
      1 2.28 (0.0898) 4 2.46 (0.0969)
      2 2.34 (0.0921) 5 2.52 (0.0992)
      3 2.40 (0.0945) 6 2.58 (0.1016)
    2. A0136AK

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

      Tech Tips

      Do not damage the journal surface of the input shaft.

  16. INSPECT 4TH GEAR THRUST CLEARANCE

    A0138BD

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

      Standard clearance
      0.1 to 0.55 mm (0.0039 to 0.0217 in.)
      Maximum clearance
      0.55 mm (0.0217 in.)

  17. INSPECT 4TH GEAR RADIAL CLEARANCE

    A013612

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

      Standard clearance
      0.015 to 0.058 mm (0.0006 to 0.0023 in.)
      Maximum clearance
      0.058 mm (0.0023 in.)

      If the clearance is exceeds the maximum, replace the 4th gear needle roller bearing or the shaft.

  18. INSTALL 5TH GEAR BEARING SPACER

    A0138A1

    1. Coat the 5th gear bearing spacer with gear oil, and install it onto the input shaft.

  19. INSTALL 5TH GEAR NEEDLE ROLLER BEARING

    A0136ZC

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

  20. INSTALL 5TH GEAR

    A0135TQ

    1. Coat the 5th gear with gear oil, and install it onto the input shaft.

  21. INSTALL 5TH GEAR SYNCHRONIZER RING

    A0136NK

    1. Coat the 5th gear synchronizer ring with gear oil, then install it onto the input shaft.

  22. INSTALL TRANSMISSION CLUTCH HUB NO.3


    1. A01373Y

      Install 3 shifting keys No. 3, 2 shifting key springs No. 1 and transmission hub sleeve No. 3 onto transmission clutch hub No. 3.

      Note

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

    2. Place the 5th gear synchronizer ring on the 5th gear, and align the synchronizer ring slots with shifting keys No. 3.

    3. A0136CJE01

      Using SST and a press, install No. 3 hub sleeve into the input shaft.

      SST
      09515-10010

      Note

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

  23. INSTALL INPUT SHAFT REAR RADIAL BALL BEARING


    1. A0137KHE01

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

      SST
      09515-10010

  24. INSPECT 5TH GEAR THRUST CLEARANCE

    A0137MU

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

      Standard clearance
      0.10 to 0.50 mm (0.0039 to 0.0197 in.)
      Maximum clearance
      0.50 mm (0.0197 in.)

  25. INSPECT 5TH GEAR RADIAL CLEARANCE

    A0137C1

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

      Standard clearance
      0.015 to 0.058 mm (0.0006 to 0.0023 in.)
      Maximum clearance
      0.058 mm (0.0023 in.)

      If the clearance exceeds the maximum, replace the 5th gear needle roller bearing or the shaft.