INPUT SHAFT REASSEMBLY

PROCEDURE


  1. INSTALL FRONT INPUT SHAFT BEARING


    1. A005KB4

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

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    1. A005LMM

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

  3. INSTALL 3RD GEAR


    1. A005H9A

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

  4. INSTALL NO. 3 SYNCHRONIZER RING


    1. A005GF4

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

  5. INSTALL NO. 2 TRANSMISSION CLUTCH HUB


    1. Coat the No. 2 transmission hub with manual transaxle oil.

    2. A005GQR

      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. A005I64E07

      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) 1 2.32 (0.0913)
      2 2.37 (0.0933) 3 2.42 (0.0953)
      4 2.47 (0.0972) 5 2.52 (0.0992)
      6 2.57 (0.1012) 7 2.62 (0.1031)
    2. A005H2B

      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. A005I7M

      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 manual transaxle oil.

    2. A005H2WE08
      Text in Illustration
      *a 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. A005IBV

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

  10. INSTALL 4TH GEAR NEEDLE ROLLER BEARING


    1. A005GNO

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

  11. INSTALL OUTER 2ND SYNCHRONIZER RING


    1. A005IYI

      Coat the outer 2nd synchronizer ring with manual transaxle 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. A005JT0

      Coat the 4th gear with manual transaxle 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. A005IJK

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

  14. INSTALL INNER 5TH GEAR BEARING RACE


    1. A005LNR

      Coat the inner 5th gear bearing race with manual transaxle 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. A005GX8

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

  16. INSTALL 5TH GEAR


    1. A005MEK

      Coat the 5th gear with manual transaxle 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. A005GF6

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

  18. INSTALL NO. 3 TRANSMISSION CLUTCH HUB


    1. Coat the No. 3 transmission hub with manual transaxle oil.

    2. A005LSE

      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. A005JKDE07

      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. A005INJ

      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 manual transaxle oil.

    2. A005KDR

      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. A005MC7

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

  22. INSTALL INNER 6TH GEAR BEARING RACE


    1. A005IVN

      Coat the inner 6th gear bearing race with manual transaxle 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. A005I4O

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

  24. INSTALL NO. 5 SYNCHRONIZER RING


    1. A005HFO

      Coat the No. 5 synchronizer ring with manual transaxle 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. A005LNP

      Coat the 6th gear sub-assembly with manual transaxle oil and install it onto the input shaft.

      Note

      Install the 6th gear sub-assembly as shown in the illustration.

  26. INSTALL REAR INPUT SHAFT RADIAL BALL BEARING


    1. A005JZTE06

      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) B 1.70 (0.0669)
      C 1.75 (0.0689) D 1.80 (0.0709)
      E 1.85 (0.0728) F 1.90 (0.0748)
      G 1.95 (0.0768) H 2.00 (0.0787)
      J 2.05 (0.0807) K 2.10 (0.0827)
      L 2.15 (0.0846) M 2.20 (0.0866)
      N 2.25 (0.0886) P 2.30 (0.0906)
    2. A005GY9

      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 new 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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