INPUT SHAFT REASSEMBLY

PROCEDURE


  1. INSTALL FRONT INPUT SHAFT BEARING


    1. A01LDVDN01

      Using SST and a press, install a new front input shaft bearing to the manual transmission case sub-assembly.

      SST
      09316-60011   ( 09316-00011, 09316-00061 )
      09527-20011
    2. A01LGBW

      Select a new snap ring that will allow minimal axial play.

      Standard clearance
      0.1 mm (0.00394 in.) or less
      Standard Snap Ring
      Part No. Mark Thickness
      90520-T0142 A 2.65 to 2.70 mm (0.1044 to 0.1062 in.)
      90520-T0143 B 2.70 to 2.75 mm (0.1063 to 0.1082 in.)
      90520-T0144 C 2.75 to 2.80 mm (0.1083 to 0.1102 in.)
      90520-T0145 D 2.80 to 2.85 mm (0.1103 to 0.1122 in.)
      90520-T0146 E 2.85 to 2.90 mm (0.1122 to 0.1141 in.)
      90520-T0147 F 2.90 to 2.95 mm (0.1142 to 0.1161 in.)

    3. Using a snap ring expander, install the snap ring to the input shaft.

  2. INSTALL 5TH GEAR NEEDLE ROLLER BEARING


    1. A01L9WB

      Coat the 5th gear needle roller bearing with gear oil and install it to the input shaft.

  3. INSTALL 5TH GEAR


    1. A01LBZ6

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

  4. INSTALL NO. 3 SYNCHRONIZER RING


    1. A01LFAM

      Coat the No. 3 synchronizer ring with gear oil, and then install it to the input shaft.

  5. INSTALL NO. 3 TRANSMISSION CLUTCH HUB


    1. A01L8PSC01
      *1 Protrusion of the No. 3 Synchronizer Ring
      *2 Groove of the No. 3 Transmission Clutch Hub

      Using SST and press, install the No. 3 transmission clutch hub to the input shaft.

      SST
      09308-14010

      Note

      Align the protrusion of the No. 3 synchronizer ring with the groove of the No. 3 transmission clutch hub as shown in the illustration

  6. INSTALL CLUTCH HUB SET SHAFT SNAP RING


    1. A01LAW4

      Select a new clutch hub set shaft snap ring that will allow minimal axial play.

      Standard clearance
      0.1 mm (0.00394 in.) or less
      Standard Snap Ring
      Part No. Mark Thickness
      90520-T0148 A 1.80 to 1.85 mm (0.0709 to 0.0728 in.)
      90520-T0149 B 1.85 to 1.90 mm (0.0729 to 0.0748 in.)
      90520-T0150 C 1.90 to 1.95 mm (0.0749 to 0.0767 in.)
      90520-T0151 D 1.95 to 2.00 mm (0.0768 to 0.0787 in.)
      90520-T0152 E 2.00 to 2.05 mm (0.0788 to 0.0807 in.)
      90520-T0153 F 2.05 to 2.10 mm (0.0808 to 0.0826 in.)

    2. Using a snap ring expander, install the clutch hub set shaft snap ring to the input shaft.

  7. INSTALL NO. 1 SYNCHROMESH SHIFTING KEY


    1. A01LCEH

      Install the 3 No. 1 synchromesh shifting keys to the No. 3 transmission clutch hub.

  8. INSTALL NO. 2 TRANSMISSION HUB SLEEVE


    1. A01L9YW

      Apply a light coat of gear oil to the sleeve and hub.

    2. Install the No. 2 transmission hub sleeve to the No. 3 transmission clutch hub.

  9. INSTALL 6TH GEAR SPACER


    1. A01LE9J

      Coat the 6th gear spacer with gear oil, and then install it to the input shaft.

  10. INSTALL 6TH GEAR NEEDLE ROLLER BEARING


    1. A01LBJJ

      Coat the 6th gear needle roller bearing with gear oil, and then install it to the input shaft.

  11. INSTALL NO. 3 SYNCHRONIZER RING


    1. A01L8OKC01
      *a Protrusion
      *b Groove

      Coat the No. 3 synchronizer ring with gear oil, and then install it to the No. 3 transmission clutch hub.

      Note

      Align the protrusion of the No. 3 synchronizer ring with the groove of the No. 3 transmission clutch hub.

  12. INSTALL 6TH GEAR SUB-ASSEMBLY


    1. A01L8EC

      Coat the 6th gear sub-assembly with gear oil, and then install it to the input shaft.

      Tech Tips

      Make sure that the 6th gear sub-assembly faces the correct direction as shown in the illustration.

    2. Check that the 6th gear sub-assembly and No. 3 synchronizer ring move smoothly.

  13. INSTALL GEAR THRUST WASHER STRAIGHT PIN


    1. A01L9A8

      Install the gear thrust washer straight pin to the input shaft.

  14. INSTALL 3RD GEAR THRUST WASHER


    1. A01L82XC01
      *1 Gear Thrust Washer Straight Pin
      *2 3rd Gear Thrust Washer
      *a Groove

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

      Tech Tips

      Align the groove of the 3rd gear thrust washer with the gear thrust washer straight pin.

  15. INSTALL GEAR THRUST WASHER SHAFT SNAP RING


    1. A01LEI8

      Select a new gear thrust washer shaft snap ring that will allow minimal axial play.

      Standard clearance
      0.1 mm (0.00394 in.) or less
      Standard Snap Ring
      Part No. Mark Thickness
      90520-T0155 A 2.07 to 2.12 mm (0.0815 to 0.0834 in.)
      90520-T0156 B 2.12 to 2.17 mm (0.0835 to 0.0854 in.)
      90520-T0157 C 2.17 to 2.22 mm (0.0855 to 0.0874 in.)
      90520-T0158 D 2.22 to 2.27 mm (0.0875 to 0.0893 in.)
      90520-T0159 E 2.27 to 2.32 mm (0.0894 to 0.0913 in.)
      90520-T0160 F 2.32 to 2.37 mm (0.0914 to 0.0933 in.)

    2. Using a snap ring expander, install the gear thrust washer shaft snap ring to the input shaft.

  16. INSTALL 3RD GEAR SPACER


    1. A01LDW0

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

  17. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    1. A01LCU4

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

  18. INSTALL 3RD GEAR


    1. A01LEJT

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

  19. INSTALL NO. 3 SYNCHRONIZER RING SET


    1. A01LD6CC01
      *a Groove
      *b Protrusion

      Coat the No. 3 synchronizer ring set with gear oil, and then install it to the input shaft.

      Note

      Align the protrusion of the No. 3 synchronizer ring set with the groove of the 3rd gear.

  20. INSTALL NO. 2 TRANSMISSION CLUTCH HUB


    1. Using SST, set the input shaft

      SST
      09527-20011

    2. Using SST and a press, install the No. 2 transmission clutch hub to the input shaft.

    3. A01LABQC01
      *a Hole of the No. 2 transmission Clutch Hub
      *b Groove of the No. 2 transmission Clutch Hub
      *c Protrusion of the No. 3 Synchronizer Ring (middle ring)
      *d Protrusion of the No. 3 Synchronizer Ring

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

      Tech Tips


      • Align the protrusion of the No. 3 synchronizer ring set (middle ring) with the hole of the No. 2 transmission clutch hub as shown in the illustration

      • Align the protrusion of the No. 2 synchronizer ring set with the groove of the No. 2 transmission clutch hub as shown in the illustration

    4. A01LE33

      Using SST and a press, install the No. 3 transmission clutch hub to the input shaft.

      SST
      09527-20011

  21. INSTALL NO. 1 SYNCHROMESH SHIFTING KEY


    1. A01LGBT

      Install the 3 No. 1 synchromesh shifting keys to the No. 2 transmission clutch hub.

  22. INSTALL NO. 2 TRANSMISSION HUB SLEEVE


    1. A01LG2I

      Apply a light coat of gear oil to the sleeve and hub.

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

  23. INSTALL NO. 2 CLUTCH HUB SETTING SHAFT SNAP RING


    1. A01LBC0

      Select a new No. 2 clutch hub setting shaft snap ring that will allow minimal axial play.

      Standard clearance
      0.1 mm (0.00394 in.) or less
      Standard Snap Ring
      Part No. Mark Thickness
      90520-T0161 A 2.50 to 2.55 mm (0.0983 to 0.1004 in.)
      90520-T0162 B 2.55 to 2.60 mm (0.1004 to 0.1023 in.)
      90520-T0163 C 2.60 to 2.65 mm (0.1024 to 0.1043 in.)
      90520-T0164 D 2.65 to 2.70 mm (0.1044 to 0.1062 in.)
      90520-T0165 E 2.70 to 2.75 mm (0.1063 to 0.1082 in.)
      90520-T0166 F 2.75 to 2.80 mm (0.1083 to 0.1102 in.)

    2. Using a brass bar and hammer, install the No. 2 clutch hub setting shaft snap ring to the input shaft.

  24. INSPECT 3RD GEAR THRUST CLEARANCE

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  25. INSPECT 3RD GEAR RADIAL CLEARANCE

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  26. INSPECT 6TH GEAR SUB-ASSEMBLY THRUST CLEARANCE

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  27. INSPECT 6TH GEAR SUB-ASSEMBLY RADIAL CLEARANCE

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  28. INSPECT 5TH GEAR THRUST CLEARANCE

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  29. INSPECT 5TH GEAR RADIAL CLEARANCE

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