INPUT SHAFT REASSEMBLY


  1. INSTALL FRONT INPUT SHAFT BEARING


    1. A01170B

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

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    1. A011BTJ

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

  3. INSTALL 3RD GEAR


    1. A0119MI

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

  4. INSTALL NO. 3 SYNCHRONIZER RING


    1. A0119IT

      Coat the No. 3 synchronizer ring with gear oil and install it onto the 3rd gear.

  5. INSTALL NO. 2 TRANSMISSION CLUTCH HUB


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

    2. A01194L

      Install the No. 2 transmission clutch hub onto the input shaft.

      Note

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

    3. A011BU9E01

      Using SST and a press, install the No. 2 transmission clutch hub onto 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 snap ring that will allow minimal axial play.

      Standard clearance
      0.1 mm (0.00394 in.) or less
      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. A011AYD

      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. A0117NL

      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. A0117EFE02
      Text in Illustration
      *1 Align

      Install the No. 2 transmission clutch hub onto 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. A011B66

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

  10. INSTALL 4TH GEAR NEEDLE ROLLER BEARING


    1. A011BY3

      Coat the 4th gear needle roller bearing and 4th gear bearing spacer with gear oil and install them onto the No. 2 transmission clutch hub.

  11. INSTALL OUTER 2ND SYNCHRONIZER RING


    1. A0117AC

      Coat the outer 2nd gear synchronizer ring with gear oil and install it onto 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. A011ANL

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

      Note

      Install the 4th gear as shown in the illustration.

  13. INSTALL INNER 5TH GEAR BEARING RACE LOCK BALL


    1. A0118JW

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

  14. INSTALL INNER 5TH GEAR BEARING RACE


    1. A01177M

      Coat the inner 5th gear bearing race with gear oil and install it onto 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. A0117CN

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

  16. INSTALL 5TH GEAR


    1. A01189E

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

      Note

      Install the 5th gear as shown in the illustration.

  17. INSTALL NO. 5 SYNCHRONIZER RING


    1. A0118BH

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

  18. INSTALL NO. 3 TRANSMISSION CLUTCH HUB


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

    2. A011AUQ

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

      Note

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

    3. A011AEGE01

      Using SST and a press, install 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. 3 synchronizer ring with the cutout of the No. 5 transmission clutch hub.

  19. INSTALL NO. 3 SYNCHROMESH SHIFTING KEY


    1. A0118PQ

      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. A011AO8

      Install the No. 3 transmission hub sleeve onto 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. A01182J

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

  22. INSTALL INNER 6TH GEAR BEARING RACE


    1. A0118FJ

      Coat the inner 6th gear bearing race with gear oil and install it onto 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. A0118C8

      Coat the 6th gear needle roller bearing and inner 6th gear bearing race with gear oil and install them onto the input shaft.

  24. INSTALL NO. 5 SYNCHRONIZER RING


    1. A0118KS

      Coat the No. 5 synchronizer ring with gear oil and install it onto 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. A0116X7

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

      Note

      Install the 6th gear as shown in the illustration.

  26. INSTALL REAR INPUT SHAFT RADIAL BALL BEARING


    1. A0119S5E01

      Using SST and a press, install the rear input shaft radial ball bearing onto 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
      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. A011AUS

      Using a snap ring expander, install the 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


    1. A011AE3

      Using a dial indicator, measure the 3rd gear radial clearance.

      Standard clearance
      0.009 to 0.050 mm (0.000354 to 0.0197 in.)
      Maximum clearance
      0.050 mm (0.0197 in.)

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

  29. INSPECT 4TH GEAR RADIAL CLEARANCE


    1. A011AHS

      Using a dial indicator, measure the 4th gear radial clearance between the gear and shaft.

      Standard clearance
      0.009 to 0.050 mm (0.000354 to 0.0197 in.)
      Maximum clearance
      0.050 mm (0.0197 in.)

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

  30. INSPECT 5TH GEAR RADIAL CLEARANCE


    1. A0118BO

      Using a dial indicator, measure the 5th gear radial clearance between the gear and shaft.

      Standard clearance
      0.009 to 0.045 mm (0.000354 to 0.00177 in.)
      Maximum clearance
      0.045 mm (0.00177 in.)

      If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing, inner 5th gear bearing race or input shaft.

  31. INSPECT 6TH GEAR RADIAL CLEARANCE


    1. A0117VT

      Using a dial indicator, measure the 6th gear radial clearance between the gear and shaft.

      Standard clearance
      0.009 to 0.075 mm (0.000354 to 0.00295 in.)
      Maximum clearance
      0.075 mm (0.00295 in.)

      If the clearance exceeds the maximum, replace the 6th gear, 6th gear needle roller bearing, inner 6th gear bearing race or input shaft.

  32. INSPECT 3RD GEAR THRUST CLEARANCE


    1. A0117N7

      Using a dial indicator, measure the 3rd gear thrust clearance.

      Standard clearance
      0.15 to 0.43 mm (0.00591 to 0.0169 in.)
      Maximum clearance
      0.43 mm (0.0169 in.)

      If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 3rd gear or input shaft.

  33. INSPECT 4TH GEAR THRUST CLEARANCE


    1. A0118TJ

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

      Standard clearance
      0.15 to 0.56 mm (0.00591 to 0.0220 in.)
      Maximum clearance
      0.56 mm (0.0220 in.)

      If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 4th gear or input shaft.

  34. INSPECT 5TH GEAR THRUST CLEARANCE


    1. A0119A0

      Using a dial indicator, measure the 5th gear thrust clearance.

      Standard clearance
      0.15 to 0.43 mm (0.00591 to 0.0169 in.)
      Maximum clearance
      0.43 mm (0.0169 in.)

      If the clearance exceeds the maximum, replace the No. 3 transmission clutch hub, 5th gear or input shaft.

  35. INSPECT 6TH GEAR THRUST CLEARANCE


    1. A0119X5

      Using a dial indicator, measure the 6th gear thrust clearance.

      Standard clearance
      0.15 to 0.43 mm (0.00591 to 0.0169 in.)
      Maximum clearance
      0.43 mm (0.0169 in.)

      If the clearance exceeds the maximum, replace the No. 3 transmission clutch hub, 6th gear or input shaft.