INPUT SHAFT REASSEMBLY


  1. INSTALL FRONT INPUT SHAFT BEARING


    1. A01IOYSE01

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

      SST
      09527-21011

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    1. A01IS6L

      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. A01IUMO

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

  4. INSTALL NO. 3 SYNCHRONIZER RING


    1. A01ITC5

      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. A01IQWF

      Temporarily install 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. A01IPZSE01

      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 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 2.27 mm (0.0894 in.) 4 2.47 mm (0.0972 in.)
      1 2.32 mm (0.0913 in.) 5 2.52 mm (0.0992 in.)
      2 2.37 mm (0.0933 in.) 6 2.57 mm (0.101 in.)
      3 2.42 mm (0.0953 in.) 7 2.62 mm (0.103 in.)
    2. A01IUG3

      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. A01IQNZ

      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. A01IU2ME02
      Text in Illustration
      *1 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 protrusions of the No. 2 transmission hub sleeve with the cutouts of the No. 2 transmission clutch hub.

  9. INSTALL 4TH GEAR BEARING SPACER


    1. A01IP0W

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

  10. INSTALL 4TH GEAR NEEDLE ROLLER BEARING


    1. A01IPTC

      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.

  11. INSTALL OUTER 2ND SYNCHRONIZER RING


    1. A01ITHH

      Coat the outer 2nd 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. A01IR5C

      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. A01IONP

      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. A01IT5E

      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. A01IQD1

      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.

  16. INSTALL 5TH GEAR


    1. A01ISI9

      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


    1. A01IS27

      Coat the No. 5 synchronizer ring 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. A01IR83

      Temporarily 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. A01IUN5E01

      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. A01IN4H

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

  20. INSTALL NO. 3 TRANSMISSION HUB SLEEVE


    1. A01ITU4

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

    2. 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 LOCK BALL


    1. A01INER

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

  22. INSTALL INNER 6TH GEAR BEARING RACE


    1. A01INIE

      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. A01IT6N

      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.

  24. INSTALL NO. 5 SYNCHRONIZER RING


    1. A01IUN8

      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.

  25. INSTALL 6TH GEAR SUB-ASSEMBLY


    1. A01IQFA

      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. A01IRRDE01

      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
      Standard Snap Ring Thickness
      Mark Specified Condition Mark Specified Condition
      A 1.65 mm (0.0649 in.) H 2.00 mm (0.0787 in.)
      B 1.70 mm (0.0669 in.) J 2.05 mm (0.0807 in.)
      C 1.75 mm (0.0689 in.) K 2.10 mm (0.0827 in.)
      D 1.80 mm (0.0709 in.) L 2.15 mm (0.0846 in.)
      E 1.85 mm (0.0728 in.) M 2.20 mm (0.0866 in.)
      F 1.90 mm (0.0748 in.) N 2.25 mm (0.0886 in.)
      G 1.95 mm (0.0768 in.) P 2.30 mm (0.0906 in.)
    2. A01IU7M

      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.

  28. INSPECT 3RD GEAR RADIAL CLEARANCE


    1. A01IPXG

      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 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.

  29. INSPECT 4TH GEAR RADIAL CLEARANCE


    1. A01IRKH

      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 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.

  30. INSPECT 5TH GEAR RADIAL CLEARANCE


    1. A01IPEC

      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 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.

  31. INSPECT 6TH GEAR RADIAL CLEARANCE


    1. A01ISP8

      Using a dial indicator, measure the 6th 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 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.

  32. INSPECT 3RD GEAR THRUST CLEARANCE


    1. A01IUID

      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 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.

  33. INSPECT 4TH GEAR THRUST CLEARANCE


    1. A01IUBL

      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 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.

  34. INSPECT 5TH GEAR THRUST CLEARANCE


    1. A01IOSD

      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 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.

  35. INSPECT 6TH GEAR THRUST CLEARANCE


    1. A01IRL4

      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 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.