ПЕРВИЧНЫЙ ВАЛ ПОВТОРНАЯ СБОРКА

PROCEDURE


  1. INSTALL FRONT INPUT SHAFT BEARING


    1. A012IP7

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

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    1. A012IVE

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

  3. INSTALL 3RD GEAR


    1. A012H3F

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

  4. INSTALL NO. 3 SYNCHRONIZER RING


    1. A012I7S

      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. A012M1L

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

      Note

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

    3. A012L51N07

      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 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 (0.1012)
      3 2.42 (0.0953) 7 2.62 (0.1031)
    2. A012ID9

      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. A012GJ0

      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. A012H9UC04
      *a Align

      Install the No. 2 transmission clutch hub to 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. A012JFF

      Install the 4th gear bearing spacer to the No. 2 clutch hub setting shaft snap ring.

  10. INSTALL 4TH GEAR NEEDLE ROLLER BEARING


    1. A012IEU

      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. A012FR3

      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. A012I0N

      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. A012F78

      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. A012FIG

      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. A012KH5

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

  16. INSTALL 5TH GEAR


    1. A012JUE

      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. A012N6J

      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. A012N2F

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

      Note

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

    3. A012MHLN07

      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 with the cutout of the No. 3 transmission clutch hub.

  19. INSTALL NO. 3 SYNCHROMESH SHIFTING KEY


    1. A012IX4

      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 gear oil.

    2. A012LYE

      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.

  21. INSTALL INNER 6TH GEAR BEARING RACE LOCK BALL


    1. A012LES

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

  22. INSTALL INNER 6TH GEAR BEARING RACE


    1. A012F2L

      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. A012LE3

      Coat the 6th gear needle roller bearing with gear oil and install the 6th gear needle roller bearing to the input shaft.

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


    1. A012I5F

      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, 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. A012M5P

      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. A012KG7N06

      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. A012I00

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

  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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