Using SST and a press, install the input shaft front bearing to the input shaft.

• SST
• 09950-00020

• УКАЗАНИЕ:

• Make sure that the groove of the bearing faces the correct direction as shown in the illustration.

Select a new snap ring that will allow minimal axial play.

• Standard clearance:
• 0.1 mm (0.00394 in.) or less

• Standard Snap Ring:

• Part No.	Mark	Thickness
  90520-31026	A	2.65 to 2.70 mm (0.1043 to 0.1063 in.)
  90520-31027	B	2.70 to 2.75 mm (0.1063 to 0.1083 in.)
  90520-31028	C	2.75 to 2.80 mm (0.1083 to 0.1102 in.)
  90520-31029	D	2.80 to 2.85 mm (0.1102 to 0.1122 in.)
  90520-31030	E	2.85 to 2.90 mm (0.1122 to 0.1142 in.)
  90520-31031	F	2.90 to 2.95 mm (0.1142 to 0.1161 in.)

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

Apply a light coat of gear oil to the sleeve and hub.

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

Install one of the balls to each shifting key.

Install one of the springs to each shifting key.

Install the shifting keys with balls and springs to the No. 2 clutch hub.

• УКАЗАНИЕ:

• Make sure that the No. 2 clutch hub faces the correct direction as shown in the illustration.

• ПРИМЕЧАНИЕ:

• Be careful to prevent the balls from flying off.

Apply a light coat of gear oil to the sleeve and hub.

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

Install one of the balls to each shifting key.

Install one of the springs to each shifting key.

Install the shifting keys with balls and springs to the No. 3 clutch hub.

• УКАЗАНИЕ:

• Make sure that the No. 2 clutch hub faces the correct direction as shown in the illustration.

• ПРИМЕЧАНИЕ:

• Be careful to prevent the balls from flying off.

Coat the 4th gear needle roller bearing with gear oil, and then install it to the input shaft.

Coat the 4th gear and No. 3 synchronizer ring with gear oil, and then install them to the input shaft.

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

• SST
• 09308-14010

• УКАЗАНИЕ:

• Align the groove of the clutch hub of the synchronizer ring with the protrusion.

Check that the gear and synchronizer ring move smoothly.

Select a new snap ring that will allow minimal axial play.

• Standard clearance:
• 0.1 mm (0.00394 in.) or less

• Standard Snap Ring:

• Part No.	Mark	Thickness
  90520-42012	A	1.80 to 1.85 mm (0.0709 to 0.0728 in.)
  90520-42013	B	1.85 to 1.90 mm (0.0728 to 0.0748 in.)
  90520-42014	C	1.90 to 1.95 mm (0.0748 to 0.0767 in.)
  90520-42015	D	1.95 to 2.00 mm (0.0767 to 0.0787 in.)
  90520-42016	E	2.00 to 2.05 mm (0.0787 to 0.0807 in.)
  90520-42017	F	2.05 to 2.10 mm (0.0807 to 0.0826 in.)
  90520-42018	G	2.10 to 2.15 mm (0.0826 to 0.0846 in.)

Using a snap ring expander, install the snap ring to the input shaft.

Coat the No. 2 synchronizer ring set with gear oil, and then install it to the input shaft.

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

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

Install the straight pin to the input shaft.

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

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

• УКАЗАНИЕ:

• Align the groove of the gear thrust washer with the straight pin.

Select a new snap ring that will allow minimal axial play.

• Standard clearance:
• 0.1 mm (0.00394 in.) or less

• Standard Snap Ring:

• Part No.	Mark	Thickness
  90520-39026	A	2.07 to 2.12 mm (0.0815 to 0.0835 in.)
  90520-39027	B	2.12 to 2.17 mm (0.0835 to 0.0854 in.)
  90520-39028	C	2.17 to 2.22 mm (0.0854 to 0.0874 in.)
  90520-39029	D	2.22 to 2.27 mm (0.0874 to 0.0894 in.)
  90520-39030	E	2.27 to 2.32 mm (0.0894 to 0.0913 in.)
  90520-39031	F	2.32 to 2.37 mm (0.0913 to 0.0933 in.)

Using a snap ring expander, install the snap ring to the input shaft.

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

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

Install the 6th gear to the input shaft.

Install the synchronizer ring to the input shaft.

Using SST and a press, install the clutch hub to the input shaft.

• SST
• 09309-37010
  09950-00020

Check that the gear and synchronizer ring move smoothly.

Select a new snap ring that will allow minimal axial play.

• Standard clearance:
• 0.1 mm (0.00394 in.) or less

• Standard Snap Ring:

• Part No.	Mark	Thickness
  90520-33022	A	2.10 to 2.15 mm (0.0827 to 0.0847 in.)
  90520-33023	B	2.15 to 2.20 mm (0.0847 to 0.0866 in.)
  90520-33024	C	2.20 to 2.25 mm (0.0866 to 0.0886 in.)
  90520-33025	D	2.25 to 2.30 mm (0.0886 to 0.0906 in.)
  90520-33026	E	2.30 to 2.35 mm (0.0906 to 0.0925 in.)
  90520-33027	F	2.35 to 2.40 mm (0.0925 to 0.0945 in.)
  90520-33028	G	2.40 to 2.45 mm (0.0945 to 0.0965 in.)

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

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

• Standard clearance:
• 0.20 to 0.49 mm (0.00788 to 0.0193 in.)

If the clearance is outside the specification, replace the gear, spacer or shaft.

• УКАЗАНИЕ:

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

Using a feeler gauge, measure the 3rd gear thrust clearance.

• Standard clearance:
• 0.09 to 0.52 mm (0.00355 to 0.0205 in.)

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

• УКАЗАНИЕ:

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

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

• Standard clearance:
• 0.12 to 0.38 mm (0.00473 to 0.0150 in.)

If the clearance is outside the specification, replace the gear, clutch hub or shaft.

• УКАЗАНИЕ:

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

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

• Standard clearance:
• 0.015 to 0.065 mm (0.000591 to 0.00255 in.)

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

• УКАЗАНИЕ:

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

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

• Standard clearance:
• 0.015 to 0.067 mm (0.000591 to 0.00263 in.)

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

• УКАЗАНИЕ:

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

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

• Standard clearance:
• 0.015 to 0.051 mm (0.000591 to 0.00200 in.)

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

• УКАЗАНИЕ:

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

Using a dial indicator and 2 V-blocks, measure the shaft runout.

• Maximum runout:
• 0.03 mm (0.00118 in.)

If the runout is more than the maximum, replace the input shaft.

Using a micrometer, measure the journal diameter of each input shaft journal at the specified positions.

• Standard Journal Diameter:

• Item	Specified Condition
  Journal A	34.002 to 34.015 mm (1.3387 to 1.3392 in.)
  Journal B	44.989 to 45.000 mm (1.7713 to 1.7716 in.)
  Journal C	44.985 to 45.000 mm (1.7711 to 1.7716 in.)
  Journal D	41.985 to 42.000 mm (1.6530 to 1.6535 in.)
  Journal E	32.967 to 32.974 mm (1.2979 to 1.2982 in.)

• Minimum Diameter:

• Item	Specified Condition
  Journal A	34.002 mm (1.3387 in.)
  Journal B	44.989 mm (1.7713 in.)
  Journal C	44.985 mm (1.7711 in.)
  Journal D	41.985 mm (1.6530 in.)
  Journal E	32.967 mm (1.2979 in.)

If the journal diameter is less than the minimum, replace the input shaft.

Using a cylinder gauge, measure the inside diameter of the 6th gear.

• Standard inside diameter:
• 51.015 to 51.040 mm (2.0085 to 2.0095 in.)

• Maximum inside diameter:
• 51.040 mm (2.0095 in.)

If the inside diameter is more than the maximum, replace the 6th gear.

Using a cylinder gauge, measure the inside diameter of the 3rd gear.

• Standard inside diameter:
• 51.015 to 51.040 mm (2.0085 to 2.0095 in.)

• Maximum inside diameter:
• 51.040 mm (2.0095 in.)

If the inside diameter is more than the maximum, replace the 3rd gear.

Using a cylinder gauge, measure the inside diameter of the 4th gear.

• Standard inside diameter:
• 51.015 to 51.028 mm (2.0085 to 2.0089 in.)

• Maximum inside diameter:
• 51.028 mm (2.0089 in.)

If the inside diameter is more than the maximum, replace the 4th gear.

Check the sliding condition between the No. 2 transmission hub and No. 2 transmission hub sleeve.

Check that the splines of the No. 2 transmission hub sleeve are not worn.

Using a vernier caliper, measure the width of the No. 2 transmission hub sleeve groove (A) and the thickness of the claw part of the No. 2 or No. 3 gear shift forks (B), and calculate the clearance.

• Standard clearance:
• A - B:
• 0.28 to 0.84 mm (0.0111 to 0.0331 in.) for No. 2 gear shift fork
• 0.28 to 0.66 mm (0.0111 to 0.0259 in.) for No. 3 gear shift fork

If the clearance is outside the specification, replace the No. 2 transmission hub sleeve and gear shift fork.

Using a feeler gauge, measure the clearance between the synchronizer ring and 6th gear.

• Standard clearance:
• 0.70 to 1.50 mm (0.0276 to 0.0591 in.)

• Minimum clearance:
• 0.70 mm (0.0276 in.)

If the clearance is less than the minimum, replace the synchronizer ring.

Coat the 6th gear cone with gear oil.

Check the braking effect of the synchronizer ring.

Using a feeler gauge, measure the clearance between the synchronizer ring and 3rd gear.

• Standard clearance:
• Inner:
• 1.20 to 2.20 mm (0.0472 to 0.0866 in.)
• Middle:
• 0.30 to 2.10 mm (0.0119 to 0.0826 in.)
• Outer:
• 0.80 to 1.80 mm (0.0315 to 0.0709 in.)

• Minimum clearance:
• Inner:
• 1.20 mm (0.0472 in.)
• Middle:
• 0.30 mm (0.0119 in.)
• Outer:
• 0.80 mm (0.0315 in.)

If the clearance is less than the minimum, replace the synchronizer ring.

Coat the 3rd gear cone with gear oil.

Check the braking effect of the synchronizer ring.

Using a feeler gauge, measure the clearance between the synchronizer ring and 4th gear.

• Standard clearance:
• 0.70 to 1.50 mm (0.0276 to 0.0591 in.)

• Minimum clearance:
• 0.70 mm (0.0276 in.)

If the clearance is less than the minimum, replace the synchronizer ring.

Coat the 4th gear cone with gear oil.

Check the braking effect of the synchronizer ring.

Using a micrometer, measure the thrust washer thickness.

• Standard thickness:
• 7.12 to 7.18 mm (0.2803 to 0.2827 in.)

• Minimum thickness:
• 7.12 mm (0.2803 in.)

If the thickness is less than the minimum, replace the thrust washer.

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

• Standard clearance:
• 0.20 to 0.49 mm (0.00788 to 0.0193 in.)

If the clearance is outside the specification, replace the gear, spacer or shaft.

• УКАЗАНИЕ:

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

Using a feeler gauge, measure the 3rd gear thrust clearance.

• Standard clearance:
• 0.09 to 0.52 mm (0.00355 to 0.0205 in.)

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

• УКАЗАНИЕ:

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

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

• Standard clearance:
• 0.12 to 0.38 mm (0.00473 to 0.0150 in.)

If the clearance is outside the specification, replace the gear, clutch hub or shaft.

• УКАЗАНИЕ:

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

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

• Standard clearance:
• 0.015 to 0.065 mm (0.000591 to 0.00255 in.)

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

• УКАЗАНИЕ:

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

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

• Standard clearance:
• 0.015 to 0.067 mm (0.000591 to 0.00263 in.)

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

• УКАЗАНИЕ:

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

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

• Standard clearance:
• 0.015 to 0.051 mm (0.000591 to 0.00200 in.)

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

• УКАЗАНИЕ:

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

Using 2 screwdrivers and a hammer, tap off the snap ring.

• УКАЗАНИЕ:

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

Using SST and a press, remove the No. 3 transmission clutch hub, hub sleeve, synchronizer ring and 6th gear from the input shaft.

• SST
• 09950-00020
  09950-70010(09951-07200)
  09950-60010(09951-00300)

• ПРИМЕЧАНИЕ:

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

Remove the spacer from the input shaft.

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

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

Remove the 3rd gear from the input shaft.

Remove the straight pin from the input shaft.

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

Remove the spacer from the input shaft.

Remove the No. 2 synchronizer ring set from the input shaft.

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

Using SST and a press, remove the No. 2 transmission clutch hub, hub sleeve, synchronizer ring and 4th gear from the input shaft.

• SST
• 09950-00020
  09950-60010(09951-00300)
  09950-70010(09951-07200)

• ПРИМЕЧАНИЕ:

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

Remove the 4th gear needle roller bearing from the input shaft.

Using 2 screwdrivers and a hammer, tap off the snap ring.

• УКАЗАНИЕ:

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

Using SST and a press, remove the input shaft front bearing from the input shaft.

• SST
• 09950-00020

• ПРИМЕЧАНИЕ:

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

Remove the clutch hub, 3 synchromesh shifting keys, 3 balls and 3 springs from the hub sleeve.

• УКАЗАНИЕ:

• Use a piece of cloth to prevent the balls and springs from flying off.

С помощью SST и пресса установите новый передний подшипник на первичный вал.

• SST
• 09950-60010(09951-00570)
  09950-70010(09951-07100)

• ПРИМЕЧАНИЕ:

• При установке переднего подшипника первичного вала канавка пружинного стопорного кольца должна быть направлена вперед.

Выберите пружинное стопорное кольцо, которое обеспечивает необходимый зазор между первичным валом и передним подшипником.

• Номинальный зазор:
• 0,10 мм (0,00394 дюйма) или менее

• Стандартные пружинные стопорные кольца:

• Метка	Толщина
  А	2,10 - 2,15 мм (0,0827 - 0,0846 дюйма)
  B	2,15 - 2,20 мм (0,0846 - 0,0866 дюйма)
  C	2,20 - 2,25 мм (0,0866 - 0,0886 дюйма)
  D	2,25 - 2,30 мм (0,0886 - 0,0906 дюйма)
  E	2,30 - 2,35 мм (0,0906 - 0,0925 дюйма)
  F	2,35 - 2,40 мм (0,0925 - 0,0945 дюйма)
  G	2,40 - 2,45 мм (0,0945 - 0,0965 дюйма)

С помощью съемника стопорных колец установите пружинное стопорное кольцо.

Нанесите трансмиссионное масло на подшипник первичного вала и установите его на первичный вал.

Нанесите на блокирующее кольцо синхронизатора № 2 трансмиссионное масло и установите его на первичный вал.

Нанесите трансмиссионное масло на конус первичного вала и убедитесь, что блокирующее кольцо синхронизатора № 2 не поворачивается ни одном направлении, прижимая блокирующее кольцо синхронизатора № 2.

Прижмите блокирующее кольцо синхронизатора № 2 к конусу первичного вала. Измерьте зазор между блокирующим кольцом синхронизатора № 2 и первичным валом.

• Номинальный зазор:
• 0,70 - 1,70 мм (0,0276 - 0,0669 дюйма)

Снимите блокирующее кольцо синхронизатора с первичного вала.

Снимите подшипник с первичного вала.

С помощью съемника стопорных колец снимите пружинное стопорное кольцо с первичного вала.

С помощью SST и пресса снимите передний подшипник с первичного вала.

• SST
• 09950-00020

Using SST and a press, install a new front bearing.

• SST
• 09950-60010(09951-00400)
  09950-70010(09951-07100)

Select a snap ring that will allow minimal axial play.

• Standard clearance:
• 0.10 mm (0.0039 in.) or less

• Standard Front Bearing Shaft Snap Ring:

• Mark	Thickness
  0	2.05 to 2.10 mm (0.0807 to 0.0827 in.)
  1	2.10 to 2.15 mm (0.0827 to 0.0847 in.)
  2	2.15 to 2.20 mm (0.0847 to 0.0866 in.)
  3	2.20 to 2.25 mm (0.0866 to 0.0886 in.)
  4	2.25 to 2.30 mm (0.0886 to 0.0906 in.)
  5	2.30 to 2.35 mm (0.0906 to 0.0925 in.)

Using a snap ring expander, install the snap ring.

Coat the 13 input shaft bearings with MP grease and install them to the input shaft.

Coat the No. 2 synchronizer ring with gear oil and install it to the input shaft.

Coat the input shaft cone with gear oil.

Check the braking effect of the No. 2 synchronizer ring.

Using a feeler gauge, measure the clearance between the No. 2 synchronizer ring back and input shaft spline end.

• Standard clearance:
• 1.00 to 2.00 mm (0.0394 to 0.0787 in.)