Input Shaft Assembly

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




1. INSTALL NO.2 CLUTCH HUB INTO HUB SLEEVE
a. Install the 3 springs and shifting keys to the clutch hub.
b. Install the hub sleeve to the clutch hub.

HINT: Direct identification groove of the hub sleeve to front of the transmission.




2. INSTALL NEEDLE ROLLER BEARINGS, 3RD GEAR, SYNCHRONIZER RINGS AND NO.2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT
a. Apply MP grease to the needle roller bearing.
b. Assemble the needle roller bearings into the 3rd gear.
c. Place the synchronizer rings on the gear and align the ring slots with the shifting keys.




d. Using SST and a press, install the 3rd gear and No.2 hub sleeve.
SST 09506-35010




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

Standard clearance: 0.10 - 0.45 mm (0.0039 - 0.0177 in.)
Maximum clearance: 0.50 mm (0.0197 in.)




5. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE ROLLER BEARINGS, 4TH GEAR AND RADIAL BALL BEARING
a. Install the spacer.
b. Apply MP grease to the needle roller bearings.
c. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
d. Install the 4th gear.
e. Using SST and a press, install the radial ball bearing.
SST 09506-35010




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.)
Maximum clearance: 0.60 mm (0.0236 in.)