INPUT SHAFT REASSEMBLY


  1. INSTALL FRONT INPUT SHAFT BEARING


    1. A00DPSD

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

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    1. A00DQF8

      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. A00DRSR

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

  4. INSTALL NO. 3 SYNCHRONIZER RING


    1. A00DSMA

      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. A00DTW1E01

      Using SST and a press, press 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 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. A00DPJO

      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 NO. 2 SYNCHROMESH SHIFTING KEY


    1. A00DRW7

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

  9. INSTALL 4TH GEAR BEARING SPACER


    1. A00DTV2

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

  10. INSTALL 4TH GEAR SYNCHRONIZER RING


    1. A00DUSM

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

      Note

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

  11. INSTALL 4TH GEAR


    1. A00DU69

      Coat the 2 pieces of 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 and 4th gear needle roller bearing are supplied as a set. When replacing the 4th gear or 4th gear needle roller bearing, replace them together as a set.

    2. A00DTMZ

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

      Note

      Install the 4th gear as shown in the illustration.

  12. INSTALL INNER 5TH GEAR BEARING RACE LOCK BALL


    1. A00DQKI

      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. A00DSC3

      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. A00DQHS

      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. A00DRV1

      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. A00DTC5

      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. A00DRGHE01

      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 NO. 3 SYNCHROMESH SHIFTING KEY


    1. A00DT6Z

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

  19. INSTALL INNER 6TH GEAR BEARING RACE LOCK BALL


    1. A00DSHW

      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. A00DQQF

      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. A00DV3L

      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. A00DRLS

      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. A00DRTZ

      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. A00DU3B

      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.

  25. INSTALL REAR INPUT SHAFT RADIAL BALL BEARING


    1. A00DT7TE01

      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 m (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. A00DQNJ

      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


    1. A005VWB

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

      Standard clearance
      0.009 to 0.047 mm (0.00035 to 0.00185 in.)
      Maximum clearance
      0.047 mm (0.00185 in.)

      If the clearance is more than the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  28. INSPECT 4TH GEAR RADIAL CLEARANCE


    1. A005U44

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

      Standard clearance
      0.009 to 0.036 mm (0.00035 to 0.00142 in.)
      Maximum clearance
      0.036 mm (0.00142 in.)

      If the clearance is more than the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  29. INSPECT 5TH GEAR RADIAL CLEARANCE


    1. A005WEF

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

      Standard clearance
      0.009 to 0.045 mm (0.00035 to 0.00177 in.)
      Maximum clearance
      0.045 mm (0.00177 in.)

      If the clearance is more than the maximum, replace the 5th gear, 5th gear needle roller bearing, inner 5th gear bearing race or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  30. INSPECT 6TH GEAR RADIAL CLEARANCE


    1. A005SJE

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

      Standard clearance
      0.009 to 0.045 mm (0.00035 to 0.00177 in.)
      Maximum clearance
      0.045 mm (0.00177 in.)

      If the clearance is more than the maximum, replace the 6th gear, 6th gear needle roller bearing, inner 6th gear bearing race or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  31. INSPECT 3RD GEAR THRUST CLEARANCE


    1. A005W7N

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

      Standard clearance
      0.20 to 0.47 mm (0.00787 to 0.0185 in.)
      Maximum clearance
      0.47 mm (0.0185 in.)

      If the clearance is more than the maximum, replace the No. 2 transmission clutch hub, 3rd gear or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  32. INSPECT 4TH GEAR THRUST CLEARANCE


    1. A005WBU

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

      Standard clearance
      0.13 to 0.60 mm (0.00512 to 0.0236 in.)
      Maximum clearance
      0.60 mm (0.0236 in.)

      If the clearance is more than the maximum, replace the No. 2 transmission clutch hub, 4th gear or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  33. INSPECT 5TH GEAR THRUST CLEARANCE


    1. A005TWB

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

      Standard clearance
      0.20 to 0.47 mm (0.00787 to 0.0185 in.)
      Maximum clearance
      0.47 mm (0.0185 in.)

      If the clearance is more than the maximum, replace the No. 3 transmission clutch hub, 5th gear or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  34. INSPECT 6TH GEAR THRUST CLEARANCE


    1. A005VGK

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

      Standard clearance
      0.20 to 0.47 mm (0.00787 to 0.0185 in.)
      Maximum clearance
      0.47 mm (0.0185 in.)

      If the clearance is more than the maximum, replace the No. 3 transmission clutch hub, 6th gear or input shaft. Replace the part or parts determined to be the most likely cause of the problem.