Input Shaft (For Sedan) Reassembly

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

NOTICE:

Orient the transmission hub sleeve No.2 and transmission clutch hub No.2 correctly.

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

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

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

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

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

SST

09316-60011(09316-00021)

NOTICE:

Fit the synchromesh shifting key into the groove of the synchronizer ring correctly.

Select a snap ring that will allow minimum axial play.

Standard clearance:

0.1 mm (0.0039 in.) or less.

Snap ring thickness:

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
0	2.30 (0.0906)	3	2.48 (0.0976)
1	2.36 (0.0929)	4	2.54 (0.1000)
2	2.42 (0.0953)	5	2.60 (0.1024)

Using a brass bar and a hammer, install the snap ring onto the input shaft.

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

Coat the 4th gear needle roller bearing and 4th gear bearing spacer with gear oil and install them onto transmission clutch hub No. 2.

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

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

SST

09608-04031

Select a snap ring that will allow minimum axial play.

Standard clearance:

0.1 mm (0.0039 in.) or less

Snap ring thickness:

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
A	2.29 (0.0901)	D	2.47 (0.0972)
B	2.35 (0.0925)	E	2.53 (0.0996)
C	2.41 (0.0948)	F	2.59 (0.1019)

Using a brass bar and a hammer, install the snap ring onto the input shaft.

NOTICE:

Do not damage the journal surface of the snap ring.

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

Standard clearance:

KOYO made:

0.015 to 0.058 mm (0.0006 to 0.0023 in.)

NSK made:

0.015 to 0.056 mm (0.0006 to 0.0022 in.)

Maximum clearance:

KOYO made:

0.058 mm (0.0023 in.)

NSK made:

0.056 mm (0.0022 in.)

Using a dial gauge, measure the 4th gear radial clearance.

Standard clearance:

0.009 to 0.050 mm (0.0004 to 0.0020 in.)

Maximum clearance:

0.050 mm (0.0020 in.)

Using a dial gauge, measure the 3rd thrust clearance.

Standard clearance:

0.1 to 0.35 mm (0.0039 to 0.0138 in.)

Maximum clearance:

0.35 mm (0.0138 in.)

Using a feeler gauge, measure the 4th thrust clearance.

Standard clearance:

0.1 to 0.55 mm (0.0039 to 0.0217 in.)

Maximum clearance:

0.55 mm (0.0217 in.)