INPUT SHAFT DISASSEMBLY


  1. INSPECT 3RD GEAR THRUST CLEARANCE

    A0137WV

    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.)

  2. 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.)

  3. INSPECT 3RD GEAR RADIAL CLEARANCE

    A0138MV

    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.)
      Maximum clearance
      0.058 mm (0.0023 in.)

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

  4. INSPECT 4TH GEAR RADIAL CLEARANCE

    A0137SE

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

  5. 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.

  6. REMOVE 5TH GEAR

    A0137DYE02

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

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

      Tech Tips


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

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

      Note

      Do not excessively tighten SST.

  7. REMOVE TRANSMISSION CLUTCH HUB NO.3

    A0135VR

    1. Remove 2 shifting key springs No. 1 from transmission clutch hub No. 3.

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

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

  8. REMOVE 5TH GEAR NEEDLE ROLLER BEARING

    A0136ZC

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

  9. REMOVE 5TH GEAR BEARING SPACER

    A0138A1

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

  10. INSPECT 4TH GEAR THRUST CLEARANCE

    A0138IV

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

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

  11. REMOVE 5TH GEAR SHAFT SNAP RING

    A0136AK

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

      Tech Tips

      Do not damage the journal surface of the input shaft.

  12. REMOVE 5TH GEAR THRUST WASHER

    A0136F5

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

  13. REMOVE 5TH GEAR THRUST WASHER BALL

    A01365W

    1. Using a magnetic finger, remove the ball from the input shaft.

  14. REMOVE 4TH GEAR

    A0138HK

    1. Remove the 4th gear from the input shaft.

  15. REMOVE 4TH GEAR NEEDLE ROLLER BEARING

    A0136PL

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

  16. REMOVE 4TH GEAR BEARING SPACER

    A0137ZY

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

  17. REMOVE 4TH GEAR SYNCHRONIZER RING

    A0137LX

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

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

    A01369C

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

      Tech Tips

      Do not damage the journal surface of the input shaft.

  19. REMOVE 3RD GEAR

    A0138WKE02

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

      SST
      09950-00020

      Note

      Do not excessively tighten SST.

      Tech Tips

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

  20. REMOVE TRANSMISSION CLUTCH HUB NO.2

    A0136P7

    1. Remove 2 shifting key springs No. 1 from transmission clutch hub No. 2.

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

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

  21. REMOVE 3RD GEAR NEEDLE ROLLER BEARING

    A01360C

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

  22. REMOVE INPUT SHAFT FRONT BEARING

    A01361ME03

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

      SST
      09950-00020

      Tech Tips

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