Assembly of Input Shaft Assembly
INPUT SHAFT ASSEMBLYHINT: Coat all of the sliding and rotating surface with gear oil before assembly.
1. INSTALL 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 3RD 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 and align the ring slots with the shifting keys.
c. Using a press, install the 3rd gear and No.2 hub sleeve.
3. INSTALL SNAP RING
a. Select a snap ring that will allow minimum axial play.
b. Using a screwdriver and hammer, tap in the snap ring.
4. INSPECT 3RD GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 3rd gear thrust clearance.
Standard clearance: 0.10 - 0.35 mm (0.0039 - 0.0138 in.)
5. INSTALL SYNCHRONIZER RING, NEEDLE ROLLER BEARINGS, SPACER, 4TH GEAR AND REAR BALL BEARING
a. Apply gear oil to the needle roller bearings.
b. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
c. Using SST and a press, install the rear ball bearing.
SST 09608-12010 (09608-00070)
6. INSTALL SNAP RING
a. Select a snap ring that will allow minimum axial play.
b. Using a screwdriver and hammer, tap in the snap ring.
7. MEASURE 4TH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 4th gear thrust clearance.
Standard clearance: 0.10 - 0.55 mm (0.0039 - 0.0217 in.)