INPUT SHAFT REASSEMBLY

PROCEDURE

  1. INSTALL FRONT INPUT SHAFT BEARING

    1. G021247N01

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

      09515-10010

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING

    1. C233031

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

  3. INSTALL 3RD GEAR

    1. G021248

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

  4. INSTALL 3RD GEAR SYNCHRONIZER RING

    1. G021249

      Coat the 3rd gear synchronizer ring with gear oil, and install it to the 3rd gear.

  5. INSTALL NO. 2 TRANSMISSION CLUTCH HUB

    1. C232584C01

      *1

      No. 2 Shifting Key Spring

      *2

      No. 2 Transmission Hub Sleeve

      *3

      No. 2 Shifting Key

      *4

      No. 2 Transmission Clutch Hub

      Install the No. 2 transmission hub sleeve to the No. 2 transmission clutch hub, and then install the 3 No. 2 shifting keys and 2 No. 2 shifting key springs.

      Note:

      Assemble the No. 2 transmission hub sleeve and No. 2 transmission clutch hub in the correct order as shown in the illustration.

    2. G021250N03

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

      09506-35010

      Note:

      • Install the No. 2 transmission clutch hub in the correct direction as shown in the illustration.

      • When installing the No. 2 transmission clutch hub, align the cutout of the No. 2 transmission clutch hub with the protrusion of the 3rd gear synchronizer ring.

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

    1. G021251C03

      *a

      Mark

      Select a new No. 2 clutch hub setting shaft snap ring that allows the minimum axial play.

      Standard Clearance

      0.1 mm (0.00393 in.) or less.

      No. 2 Clutch Hub Setting Shaft Snap Ring Thickness

      Part No.

      Mark

      Thickness

      mm (in.)

      90520-32014

      A

      2.28 (0.0898)

      90520-32015

      B

      2.34 (0.0921)

      90520-32016

      C

      2.40 (0.0945)

      90520-32017

      D

      2.46 (0.0969)

      90520-32018

      E

      2.52 (0.0992)

      90520-32019

      F

      2.58 (0.1016)
    2. C303213

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

      Tip:

      Use a piece of cloth to keep the snap ring from flying off.

  7. INSTALL 4TH GEAR SYNCHRONIZER RING

    1. G021254

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

  8. INSTALL 4TH GEAR BEARING SPACER

    1. G021255

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

  9. INSTALL 4TH GEAR NEEDLE ROLLER BEARING

    1. C233030

      Coat the 4th gear needle roller bearing with gear oil, and install it to the input shaft.

  10. INSTALL 4TH GEAR

    1. G021257

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

  11. INSTALL 5TH GEAR THRUST WASHER BALL

    1. G021346

      Install the 5th gear thrust washer ball to the input shaft.

  12. INSTALL 5TH GEAR THRUST WASHER

    1. G021230

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

  13. INSTALL 5TH GEAR SHAFT SNAP RING

    1. G021347C04

      *a

      Mark

      Using the table below, select a new 5th gear shaft snap ring that makes the thrust clearance of the 5th gear thrust washer less than 0.1 mm (0.00393 in.).

      5th Gear Shaft Snap Ring Thickness

      Part No.

      Mark

      Thickness

      mm (in.)

      90520-29049

      1

      2.28 (0.0898)

      90520-29050

      2

      2.34 (0.0921)

      90520-29052

      3

      2.40 (0.0945)

      90520-29053

      4

      2.46 (0.0969)

      90520-29054

      5

      2.52 (0.0992)

      90520-29055

      6

      2.58 (0.1016)
    2. G021229

      Using a snap ring expander, install the 5th gear shaft snap ring to the input shaft.

      Note:

      Be careful not to damage the journal surface of the input shaft.

  14. INSPECT 4TH GEAR THRUST CLEARANCE

    Click here

  15. INSTALL 5TH GEAR BEARING SPACER

    1. G021227

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

  16. INSTALL 5TH GEAR NEEDLE ROLLER BEARING

    1. C233029

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

  17. INSTALL 5TH GEAR

    1. G021351

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

  18. INSTALL 5TH GEAR SYNCHRONIZER RING

    1. G021352

      Coat the 5th gear synchronizer ring with gear oil, and install it to the 5th gear.

  19. INSTALL NO. 3 TRANSMISSION CLUTCH HUB

    1. G021353C01

      *1

      No. 3 Shifting Key Spring

      *2

      No. 3 Transmission Hub Sleeve

      *3

      No. 3 Shifting Key

      *4

      No. 3 Transmission Clutch Hub

      Install the No. 3 transmission hub sleeve to the No. 3 transmission clutch hub, and then install the 3 No. 3 shifting keys and 2 No. 3 shifting key springs.

      Note:

      Assemble the No. 3 transmission hub sleeve, 3 No. 3 shifting keys and No. 3 transmission clutch hub in the correct order as shown in the illustration.

    2. Place the 5th gear synchronizer ring on the 5th gear, and align the 5th gear synchronizer ring slots with the No. 3 shifting keys.

    3. G021354N03

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

      09515-10010

      Note:

      Install the No. 3 transmission clutch hub in the correct direction as shown in the illustration.

  20. INSTALL REAR INPUT SHAFT RADIAL BALL BEARING

    1. G021355N01

      Using SST and a press, install a new rear input shaft radial ball bearing to the input shaft.

      09515-10010

  21. INSPECT 5TH GEAR RADIAL CLEARANCE

    Click here

  22. INSPECT 4TH GEAR RADIAL CLEARANCE

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  23. INSPECT 3RD GEAR RADIAL CLEARANCE

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  24. INSPECT 5TH GEAR THRUST CLEARANCE

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  25. INSPECT 3RD GEAR THRUST CLEARANCE

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