Assembly of Input Shaft Assembly

HINT: Coat all of the sliding and rotating surface with gear oil before assembly.




1. INSERT NO.2 CLUTCH HUB INTO HUB SLEEVE
a. Install the clutch hub and shifting keys to the hub sleeve.
b. Install the shifting key springs under the shifting keys.

NOTE: Install the key springs positioned so that their end gaps are not in line.




2. INSTALL THIRD GEAR, NEEDLE ROLLER BEARINGS, SYNCHRONIZER RING AND NO.2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT
a. Apply gear oil to the needle roller bearings.
b. Place the synchronizer ring on the gear.

HINT: Align the ring slots with the shifting key.




c. Using a press, install the 3rd gear and No.2 hub sleeve.




3. INSTALL SNAP RING




Select a snap ring that will allow minimum axial play and install it on the shaft.




4. MEASURE THIRD GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 3rd gear thrust clearance.

Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 in.)




5. INSTALL SYNCHRONIZER RING, NEEDLE ROLLER BEARINGS, SPACER, FOURTH GEAR AND REAR BALL BEARING
a. Apply gear oil to the needle roller bearings.
b. Install the spacer and needle roller bearings.
c. Place the synchronizer ring on the gear and align the ring slots with the shift keys.




d. Using SST, press in the rear ball bearing.
SST 09608-12010 (09668-00070)




6. INSTALL SNAP RING




Select a snap ring that will allow minimum axial play and install it on the shaft.




7. MEASURE FOURTH GEAR THRUST CLEARANCE
Using a feeler gauge, measure 4th gear thrust clearance.

Standard clearance: 0.20 - 0.45 mm (0.0078 - 0.0177 in.)