INPUT SHAFT DISASSEMBLY

PROCEDURE


  1. INSPECT 3RD GEAR THRUST CLEARANCE


    1. B003NUR

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

      Standard Clearance
      0.200 to 0.490 mm (0.0079 to 0.0192 in.)

      If the clearance is outside the specification, replace the 3rd gear, thrust washer, clutch hub or shaft.

      Tech Tips

      Replace the part or parts determined to be the most likely cause of the problem.

  2. INSPECT 3RD GEAR RADIAL CLEARANCE


    1. B003PAM

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

      Standard Clearance
      0.0150 to 0.065 mm (0.0006 to 0.0025 in.)

      If the clearance is outside the specification, replace the 3rd gear, 3rd gear needle roller bearing or shaft.

      Tech Tips

      Replace the part or parts determined to be the most likely cause of the problem.

  3. INSPECT 6TH GEAR SUB-ASSEMBLY THRUST CLEARANCE


    1. B003K6I

      Using a feeler gauge, measure the 6th gear sub-assembly thrust clearance.

      Standard Clearance
      0.150 to 0.580 mm (0.0059 to 0.0228 in.)

      If the clearance is outside the specification, replace the 6th gear sub-assembly, thrust washer, clutch hub or shaft.

      Tech Tips

      Replace the part or parts determined to be the most likely cause of the problem.

  4. INSPECT 6TH GEAR SUB-ASSEMBLY RADIAL CLEARANCE


    1. B003OIR

      Using a dial indicator, measure the 6th gear sub-assembly radial clearance.

      Standard Clearance
      0.015 to 0.067 mm (0.0006 to 0.0026 in.)

      If the clearance is outside the specification, replace the 6th gear sub-assembly, 6th gear needle roller bearing or shaft.

      Tech Tips

      Replace the part or parts determined to be the most likely cause of the problem.

  5. INSPECT 5TH GEAR THRUST CLEARANCE


    1. B003RER

      Using a feeler gauge, measure the 5th gear thrust clearance.

      Standard Clearance
      0.150 to 0.410 mm (0.0060 to 0.0161 in.)

      If the clearance is outside the specification, replace the 5th gear, thrust washer, clutch hub or shaft.

      Tech Tips

      Replace the part or parts determined to be the most likely cause of the problem.

  6. INSPECT 5TH GEAR RADIAL CLEARANCE


    1. B003LGL

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

      Standard Clearance
      0.013 to 0.054 mm (0.0006 to 0.0021 in.)

      If the clearance is outside the specification, replace the 5th gear, thrust washer, clutch hub or shaft.

      Tech Tips

      Replace the part or parts determined to be the most likely cause of the problem.

  7. REMOVE NO. 2 CLUTCH HUB SETTING SHAFT SNAP RING


    1. B003L9D

      Using 2 screwdrivers and a hammer, tap off the No. 2 clutch hub setting shaft snap ring.

      Tech Tips

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

  8. REMOVE NO. 2 TRANSMISSION HUB SLEEVE


    1. Remove the No. 2 transmission hub sleeve from the No. 2 transmission clutch hub.

  9. REMOVE NO. 1 SYNCHROMESH SHIFTING KEY


    1. Remove the 3 No. 1 synchromesh shifting keys from the No. 2 transmission clutch hub.

  10. REMOVE NO. 2 TRANSMISSION CLUTCH HUB


    1. B003N25N01

      Using SST and a press, remove the No. 2 transmission clutch hub, No. 3 synchronizer ring set and 3rd gear from the input shaft.

      SST
      09555-55010
      09950-60010   ( 09951-00410 )

      Note


      • Do not tighten SST excessively.

      • Support the input shaft by hand so that it does not fall.

  11. REMOVE 3RD GEAR NEEDLE ROLLER BEARING

    B003K25

    1. Remove the 3rd gear needle roller bearing from the input shaft.

  12. REMOVE 3RD GEAR SPACER


    1. Remove the 3rd gear spacer from the input shaft.

  13. REMOVE GEAR THRUST WASHER SHAFT SNAP RING


    1. B003RWA

      Using a snap ring expander, remove the gear thrust washer shaft snap ring from the input shaft.

  14. REMOVE 3RD GEAR THRUST WASHER


    1. Remove the 3rd gear thrust washer from the input shaft.

  15. REMOVE GEAR THRUST WASHER STRAIGHT PIN


    1. Remove the gear thrust washer straight pin from the input shaft.

  16. REMOVE 6TH GEAR SUB-ASSEMBLY


    1. Remove the 6th gear sub-assembly from the input shaft.

  17. REMOVE NO. 3 SYNCHRONIZER RING


    1. Remove the No. 3 synchronizer ring from the No. 3 transmission clutch hub.

  18. REMOVE 6TH GEAR NEEDLE ROLLER BEARING


    1. Remove the 6th gear needle roller bearing from the input shaft.

  19. REMOVE 6TH GEAR SPACER


    1. Remove the 6th gear spacer from the input shaft.

  20. REMOVE NO. 2 TRANSMISSION HUB SLEEVE


    1. Remove the No. 2 transmission hub sleeve from the No. 3 transmission clutch hub.

  21. REMOVE NO. 1 SYNCHROMESH SHIFTING KEY


    1. Remove the 3 No. 1 synchromesh shifting keys from the No. 3 transmission clutch hub.

  22. REMOVE CLUTCH HUB SET SHAFT SNAP RING


    1. B003MS9

      Using a snap ring expander, remove the clutch hub set shaft snap ring from the input shaft.

  23. REMOVE 5TH GEAR


    1. B003R4IN01

      Using SST and a press, remove the 5th gear and No. 3 transmission clutch hub from the input shaft.

      SST
      09527-20011
      09950-60010   ( 09951-00410 )

      Note

      Support the input shaft so that it does not fall.

  24. REMOVE 5TH GEAR NEEDLE ROLLER BEARING


    1. Remove the 5th gear needle roller bearing from the input shaft.

  25. REMOVE FRONT INPUT SHAFT BEARING


    1. B003NAG

      Using a snap ring expander, remove the snap ring from the input shaft.

    2. B003JFVN01

      Using SST, remove the front input shaft bearing from the input shaft.

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04020, 09955-04031, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00180 )