Input Shaft Reassembly

Using SST and a press, press in the front bearing (inner race).

SST

09608-00071

Coat the No. 2 transaxle hub sleeve with gear oil, and install it to the No. 2 transaxle clutch hub.

NOTICE:

Set the No. 2 transaxle clutch hub sleeve and the No. 2 transaxle clutch hub in the correct orientation.

Using a screwdriver, install the 3 synchromesh key springs with the 3 synchromesh shifting keys to the No. 2 transaxle clutch hub.

Coat the 3rd gear bearing with gear oil, and install it 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.

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

SST

09316-60011(09316-00041)

NOTICE:

1. Align the claw of the No. 2 clutch hub with the notch of the No. 3 synchronizer ring and install it.
   
2. Make sure that the 3rd gear can rotate.
   

Select a No. 2 clutch hub setting shaft snap ring so that the clearance between the No. 2 transaxle clutch hub and the No. 2 clutch hub setting shaft snap ring will be within the specification. Using a brass bar and hammer, install the No. 2 clutch hub setting shaft snap ring.

Standard clearance:

0.1 mm (0.004 in.) or less

Standard snap ring thickness:

Part No.	Mark	Thickness
90520-34003	H	2.30 to 2.35 mm (0.0906 to 0.0925 in.)
90520-34004	J	2.35 to 2.40 mm (0.0925 to 0.0945 in.)
90520-34005	K	2.40 to 2.45 mm (0.0945 to 0.0965 in.)
90520-34006	L	2.45 to 2.50 mm (0.0965 to 0.0984 in.)
90520-34007	M	2.50 to 2.55 mm (0.0984 to 0.1004 in.)
90520-34008	N	2.55 to 2.60 mm (0.1004 to 0.1024 in.)
90520-34009	P	2.60 to 2.65 mm (0.1024 to 0.1043 in.)

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

Coat the 2nd synchronizer outer ring (No. 4 synchronizer ring) with gear oil, and install it to the No. 2 transaxle clutch hub.

NOTICE:

Align the claw of the No. 2 clutch hub with the notch of the 2nd synchronizer outer ring (No. 4 synchronizer ring) and install it.

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

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

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

SST

09608-06041

NOTICE:

1. Install the bearing with its groove for the snap ring facing upward.
   
2. Make sure that the 3rd gear rotates.
   

Select a rear bearing shaft snap ring so that the clearance between the rear radial ball bearing and the rear bearing shaft snap ring will be within the specification. Using a brass bar and hammer, install the rear bearing shaft snap ring.

Standard clearance:

0.1 mm (0.004 in.) or less

Standard snap ring thickness:

Part No.	Mark	Thickness
90520-30008	1	2.35 to 2.40 mm (0.0925 to 0.0945 in.)
90520-30009	2	2.40 to 2.45 mm (0.0945 to 0.0965 in.)
90520-30010	3	2.45 to 2.50 mm (0.0965 to 0.0984 in.)
90520-30011	4	2.50 to 2.55 mm (0.0984 to 0.1004 in.)
90520-30012	5	2.55 to 2.60 mm (0.1004 to 0.1024 in.)
90520-30013	6	2.60 to 2.65 mm (0.1024 to 0.1043 in.)
90520-30021	7	2.65 to 2.70 mm (0.1043 to 0.1063 in.)
90520-30022	8	2.70 to 2.75 mm (0.1063 to 0.1083 in.)

Using a dial indicator, measure the radial clearance.

Standard clearance:

Bearing	Specified Condition
KOYO made	0.009 to 0.053 mm (0.0004 to 0.0021 in.)
NSK made	0.009 to 0.051 mm (0.0004 to 0.0020 in.)

Using a dial indicator, measure the radial clearance.

Standard clearance:

Bearing	Specified Condition
KOYO made	0.009 to 0.053 mm (0.0004 to 0.0021 in.)
NSK made	0.009 to 0.051 mm (0.0004 to 0.0020 in.)

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.10 to 0.35 mm (0.0039 to 0.0138 in.)

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.10 to 0.57 mm (0.0039 to 0.0224 in.)