INPUT SHAFT REASSEMBLY

PROCEDURE


  1. INSTALL FRONT INPUT SHAFT BEARING


    1. A01LV5M

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

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    1. A01LZ47

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

  3. INSTALL 3RD GEAR


    1. A01LVKE

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

  4. INSTALL NO. 3 SYNCHRONIZER RING


    1. A01LW8I

      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. A01M2VE

      Position the No. 2 transmission clutch hub on the input shaft.

      Note

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

    3. A01LXYCN01

      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
      Mark Thickness mm (in.) Mark Thickness mm (in.)
      0 2.27 (0.0894) 4 2.47 (0.0972)
      1 2.32 (0.0913) 5 2.52 (0.0992)
      2 2.37 (0.0933) 6 2.57 (0.101)
      3 2.42 (0.0953) 7 2.62 (0.103)
    2. A01LY3X

      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. A01LY2W

      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. A01M1H5C07
      *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. A01LV4Q

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

  10. INSTALL 4TH GEAR NEEDLE ROLLER BEARING


    1. A01LWSV

      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. A01M0RK

      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. A01LX9B

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

      Note

      Install the 4th gear as shown in the illustration.

  13. INSTALL INNER 5TH GEAR BEARING RACE LOCK BALL


    1. A01M02O

      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. A01M133

      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. A01LWF9

      Coat the 5th gear needle roller bearing with gear oil and install the 5th gear needle roller bearing to the inner 5th gear bearing race.

  16. INSTALL 5TH GEAR


    1. A01LZVS

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

      Note

      Install the 5th gear as shown in the illustration.

  17. INSTALL NO. 5 SYNCHRONIZER RING (for 5th Gear)


    1. A01LXUG

      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. A01LVB1

      Position the No. 3 transmission clutch hub on the input shaft.

      Note

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

    3. A01M1T2N05

      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. 5 synchronizer ring (for 5th gear) with the cutout of the No. 3 transmission clutch hub.

  19. INSTALL NO. 3 SYNCHROMESH SHIFTING KEY


    1. A01LV67

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

  20. INSTALL INNER 6TH GEAR BEARING RACE LOCK BALL


    1. A01LV2K

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

  21. INSTALL NO. 3 TRANSMISSION HUB SLEEVE


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

    2. A01M1V1

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

      Note

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

  22. INSTALL INNER 6TH GEAR BEARING RACE


    1. A01M2LW

      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. A01M2Q2

      Coat the 6th gear needle roller bearing with gear oil and install it to the inner 6th gear bearing race.

  24. INSTALL NO. 5 SYNCHRONIZER RING (for 6th Gear)


    1. A01M2FM

      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. A01M2I6

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

      Note

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

  26. INSTALL REAR INPUT SHAFT RADIAL BALL BEARING


    1. A01LZI3N04

      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
      Mark Thickness mm (in.) Mark Thickness mm (in.)
      A 1.65 (0.0650) H 2.00 (0.0787)
      B 1.70 (0.0669) J 2.05 (0.0807)
      C 1.75 (0.0689) K 2.10 (0.0827)
      D 1.80 (0.0709) L 2.15 (0.0846)
      E 1.85 (0.0728) M 2.20 (0.0866)
      F 1.90 (0.0748) N 2.25 (0.0886)
      G 1.95 (0.0768) P 2.30 (0.0906)
    2. A01M0N0

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

      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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