Input Shaft (For Hatchback) Reassembly

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

NOTICE:

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

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

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 the No. 2 transmission clutch hub 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 (0.00394 in.) or less.

Snap Ring Thickness:

Part No.	Mark	Thickness mm (in.)
90520-27046	0	2.30 (0.0906)
90520-27047	1	2.36 (0.0929)
90520-27048	2	2.42 (0.0953)
90520-27049	3	2.48 (0.0976)
90520-27050	4	2.54 (0.1000)
90520-27051	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 the No. 2 transmission clutch hub.

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

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 (0.00394 in.) or less

Snap Ring Thickness:

Part No.	Mark	Thickness mm (in.)
90520-22006	A	2.29 (0.0902)
90520-22007	B	2.35 (0.0925)
90520-22008	C	2.41 (0.0949)
90520-22009	D	2.47 (0.0972)
90520-22010	E	2.53 (0.0996)
90520-22011	F	2.59 (0.1020)

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 indicator, measure the 3rd gear radial clearance between the 3rd gear and input shaft.

Standard clearance:

JTEKT made:

0.015 to 0.058 mm (0.000591 to 0.00228 in.)

NSK made:

0.015 to 0.056 mm (0.000591 to 0.00220 in.)

Maximum clearance:

JTEKT made:

0.058 mm (0.00228 in.)

NSK made:

0.056 mm (0.00220 in.)

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

Standard clearance:

0.009 to 0.050 mm (0.000354 to 0.00197 in.)

Maximum clearance:

0.050 mm (0.00197 in.)

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

Standard clearance:

0.1 to 0.35 mm (0.00394 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 (0.00394 to 0.0217 in.)

Maximum clearance:

0.55 mm (0.0217 in.)