INPUT SHAFT REASSEMBLY

PROCEDURE


  1. INSTALL FRONT INPUT SHAFT BEARING


    1. A001VWY

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

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    1. A001TXH

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

  3. INSTALL 3RD GEAR


    1. A001VYL

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

  4. INSTALL NO. 3 SYNCHRONIZER RING


    1. A001SEZ

      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. A001W7W

      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. A001WGKN10

      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. A001XE7

      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. A001X2X

      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. A001Y5OC03
      *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. A001TE7

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

  10. INSTALL 4TH GEAR NEEDLE ROLLER BEARING


    1. A001XQR

      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. A001UXZ

      Coat the outer 2nd gear 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. A001TNH

      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. A001SOR

      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. A001T00

      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. A001YFR

      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. A001SLZ

      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. A001TBB

      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. A001V4G

      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. A001TDZN10

      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. A001SP5

      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. A001TI3

      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. A001Y8P

      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. A001W4C

      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. A001VP3

      Coat 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.

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


    1. A001W20

      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. A001VK2

      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. A001WJQN09

      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 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 (0.0649) 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. A001W7C

      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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