INPUT SHAFT REASSEMBLY

PROCEDURE


  1. INSTALL FRONT INPUT SHAFT BEARING


    1. A00YVSH

      Using a press, press the front input shaft bearing onto the input shaft.

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    1. A00YV7U

      Coat the 2 pieces of the 3rd gear needle roller bearing with gear oil and install them to the input shaft.

  3. INSTALL 3RD GEAR


    1. A00YT0S

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

  4. INSTALL NO. 3 SYNCHRONIZER RING


    1. A00YVCX

      Coat the No. 3 synchronizer ring with gear oil and install it to the 3rd gear sub-assembly.

  5. INSTALL NO. 2 TRANSMISSION CLUTCH HUB


    1. Coat the No. 2 transmission clutch hub with gear oil.

    2. A00YWQ6N01

      Using SST and a press, press the No. 2 transmission clutch hub to the input shaft.

      SST
      09316-60011   ( 09316-00011 )
      09527-21011

      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 snap ring that will allow minimal axial play.

      Standard clearance
      0.1 mm (0.00394 in.) or less
      Standard Snap Ring Thickness
      Mark Specified Condition Mark Specified Condition
      0 2.30 mm (0.0905 in.) 3 2.48 mm (0.0976 in.)
      1 2.36 mm (0.0929 in.) 4 2.54 mm (0.0999 in.)
      2 2.42 mm (0.0952 in.) 5 2.60 mm (0.1023 in.)
    2. A00YVO8

      Using a snap ring expander, install the No. 2 clutch hub setting shaft snap ring.

      Note


      • Be sure to properly install the snap ring as it easily expands.

      • Do not damage the journal surface of the snap ring.

  7. INSTALL SYNCHROMESH SHIFTING KEY


    1. A00YTR8

      Install the 3 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. Install the No. 2 transmission hub sleeve to the No. 2 transmission clutch hub.

  9. INSTALL 4TH GEAR BEARING SPACER


    1. A00YT9B

      Install the 4th gear bearing spacer to the input shaft.

  10. INSTALL 4TH GEAR SYNCHRONIZER RING


    1. A00YVI8

      Coat the No. 4 synchronizer ring with gear oil and install it to the No. 2 transmission clutch hub.

      Note

      When installing the No. 4 synchronizer ring, align the protrusion of the No. 4 synchronizer ring with the cutout of the No. 2 transmission clutch hub.

  11. INSTALL 4TH GEAR


    1. A00YXTY

      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.

      Tech Tips

      The 4th gear sub-assembly and 4th gear needle roller bearing are supplied as a set. When replacing the 4th gear sub-assembly or 4th gear needle roller bearing, replace them together as a set.

    2. A00YT3K

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

      Note

      Install the 4th gear sub-assembly as shown in the illustration.

  12. INSTALL INNER 5TH GEAR BEARING RACE LOCK BALL


    1. A00YRG5

      Coat the inner 5th gear bearing race lock ball with gear oil and install it to the input shaft.

  13. INSTALL INNER 5TH GEAR BEARING RACE


    1. A00YR0G

      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.

  14. INSTALL 5TH GEAR NEEDLE ROLLER BEARING


    1. A00YT5N

      Coat the 2 pieces of the 5th gear needle roller bearing and inner 5th gear bearing race with gear oil and install the 5th gear needle roller bearing to the input shaft.

  15. INSTALL 5TH GEAR


    1. A00YW7L

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

      Note

      Install the 5th gear as shown in the illustration.

  16. INSTALL NO. 5 SYNCHRONIZER RING


    1. A00YWO2

      Coat the No. 5 synchronizer ring with gear oil and install it to the 5th gear.

  17. INSTALL NO. 3 TRANSMISSION CLUTCH HUB


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

    2. A00YXWIN01

      Using SST and a press, press the No. 3 transmission clutch hub onto 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.

  18. INSTALL SYNCHROMESH SHIFTING KEY


    1. A00YUN3

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

  19. INSTALL INNER 6TH GEAR BEARING RACE LOCK BALL


    1. A00YV3J

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

  20. INSTALL NO. 3 TRANSMISSION HUB SLEEVE


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

    2. A00YUTV

      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


    1. A00YR65

      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.

  22. INSTALL 6TH GEAR NEEDLE ROLLER BEARING


    1. A00YUVH

      Coat the 2 pieces of the 6th gear needle roller bearing and inner 6th gear bearing race with gear oil and install the 6th gear needle roller bearing to the input shaft.

  23. INSTALL NO. 5 SYNCHRONIZER RING


    1. A00YVI2

      Coat the No. 5 synchronizer ring 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.

  24. INSTALL 6TH GEAR SUB-ASSEMBLY


    1. A00YUTL

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

      Note

      Install the 6th gear as shown in the illustration.

  25. INSTALL REAR INPUT SHAFT RADIAL BALL BEARING


    1. A00YSCAN01

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

      SST
      09527-21011
      09608-04031

  26. INSTALL REAR INPUT SHAFT BEARING SHAFT SNAP RING


    1. Select a new snap ring that will allow minimal axial play.

      Standard clearance
      0.1 mm (0.00394 in.) or less
      Standard Snap Ring Thickness
      Mark Specified Condition Mark Specified Condition
      0 1.90 mm (0.0748 in.) 6 2.26 mm (0.0889 in.)
      1 1.96 mm (0.0771 in.) 7 2.32 mm (0.0913 in.)
      2 2.02 mm (0.0795 in.) 8 2.38 mm (0.0937 in.)
      3 2.08 mm (0.0818 in.) 9 2.44 mm (0.0960 in.)
      4 2.14 mm (0.0842 in.) A 2.50 mm (0.0984 in.)
      5 2.20 mm (0.0866 in.) - -
    2. A00YWA6

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

      Note


      • Be sure to properly install the snap ring as it easily expands.

      • Do not damage the journal surface of the snap ring.

  27. INSPECT 3RD GEAR RADIAL CLEARANCE

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  28. INSPECT 4TH GEAR RADIAL CLEARANCE

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  29. INSPECT 5TH GEAR RADIAL CLEARANCE

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  30. INSPECT 6TH GEAR RADIAL CLEARANCE

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  31. INSPECT 3RD GEAR THRUST CLEARANCE

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  32. INSPECT 4TH GEAR THRUST CLEARANCE

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  33. INSPECT 5TH GEAR THRUST CLEARANCE

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  34. INSPECT 6TH GEAR THRUST CLEARANCE

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