Input Shaft Reassembly

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

Coat the 2 pieces of the 3rd gear needle roller bearing with gear oil and install them to the input shaft.

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

Coat the No. 3 synchronizer ring with gear oil and install it to the 3rd gear.

Coat the No. 2 transmission clutch hub with gear oil.

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

SST

09527-21011
09316-60011(09316-00011)

NOTICE:

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.

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	2.30 mm (0.0905 in.)	3	2.48 mm (0.0976 in.)
1	2.36 mm (0.0929 in.)	4	2.54 mm (0.0999 in.)
2	2.42 mm (0.0952 in.)	5	2.60 mm (0.1023 in.)

Using a snap ring expander, install the No. 2 clutch hub setting shaft snap ring.

NOTICE:

1. Be sure to properly install the snap ring as it easily expands.
   
2. Do not damage the journal surface of the snap ring.
   

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

Coat the No. 2 transmission hub sleeve with gear oil.

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

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

Coat 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.

HINT:

The 4th gear and 4th gear needle roller bearing are supplied as a set. When replacing the 4th gear or 4th gear needle roller bearing, replace them together as a set.

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

NOTICE:

When installing the No. 4 synchronizer ring, align the protrusion of the No. 4 synchronizer ring with the cutout of the No. 2 transmission clutch hub.

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

NOTICE:

Install the 4th gear as shown in the illustration.

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

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

NOTICE:

Align the groove of the inner 5th gear bearing race with the ball.

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.

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

NOTICE:

Install the 5th gear as shown in the illustration.

Coat the No. 5 synchronizer ring with gear oil and install it to the 5th gear.

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

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

SST

09309-37010
09527-21011

NOTICE:

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.

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

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

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

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

NOTICE:

Install the No. 3 transmission hub sleeve as shown in the illustration.

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

NOTICE:

Align the groove of the inner 6th gear bearing race with the ball.

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.

Coat the No. 5 synchronizer ring with gear oil and install it to the No. 3 transmission clutch hub.

NOTICE:

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.

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

NOTICE:

Install the 6th gear as shown in the illustration.

Using SST and a press, press the rear input shaft radial ball bearing onto the input shaft.

SST

09527-21011
09608-04031

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	1.90 mm (0.0748 in.)	6	2.26 mm (0.0889 in.)
1	1.96 mm (0.0771 in.)	7	2.32 mm (0.0913 in.)
2	2.02 mm (0.0795 in.)	8	2.38 mm (0.0937 in.)
3	2.08 mm (0.0818 in.)	9	2.44 mm (0.0960 in.)
4	2.14 mm (0.0842 in.)	A	2.50 mm (0.0984 in.)
5	2.20 mm (0.0866 in.)	-	-

Using a snap ring expander, install the rear input shaft bearing shaft snap ring.

NOTICE:

1. Be sure to properly install the snap ring as it easily expands.
   
2. Do not damage the journal surface of the snap ring.
   

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

Standard clearance:

0.009 to 0.047 mm (0.0003554 to 0.00185 in.)

Maximum clearance:

0.047 mm (0.00185 in.)

Using a dial indicator, measure the 4th gear radial clearance between the gear and shaft.

Standard clearance:

0.009 to 0.036 mm (0.000355 to 0.00142 in.)

Maximum clearance:

0.036 mm (0.00142 in.)

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

Standard clearance:

0.009 to 0.045 mm (0.000355 to 0.00177 in.)

Maximum clearance:

0.045 mm (0.00177 in.)

Using a dial indicator, measure the 6th gear radial clearance between the gear and shaft.

Standard clearance:

0.009 to 0.045 mm (0.000355 to 0.00177 in.)

Maximum clearance:

0.045 mm (0.00177 in.)

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

Standard clearance:

0.20 to 0.47 mm (0.00787 to 0.0185 in.)

Maximum clearance:

0.47 mm (0.0185 in.)

Using a dial indicator, measure the 4th gear thrust clearance.

Standard clearance:

0.13 to 0.60 mm (0.00512 to 0.0236 in.)

Maximum clearance:

0.60 mm (0.0236 in.)

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

Standard clearance:

0.20 to 0.47 mm (0.00787 to 0.0185 in.)

Maximum clearance:

0.47 mm (0.0185 in.)

Using a dial indicator, measure the 6th gear thrust clearance.

Standard clearance:

0.20 to 0.47 mm (0.00787 to 0.0185 in.)

Maximum clearance:

0.47 mm (0.0185 in.)