Input Shaft
INPUT SHAFTCOMPONENTS:
DISASSEMBLY
1. REMOVE 4TH GEAR
(a) Hold the input shaft assembly in a vise using aluminum plates.
(b) Using 2 screwdrivers and a hammer, remove the input shaft rear bearing shaft snap ring from the input shaft.
HINT: Use a shop rag or a piece of cloth to keep the snap ring from flying.
(c) Using SST and a press, remove the input shaft rear bearing and 4th gear.
SST 09950-00020
NOTICE: Do not overtighten the SST.
2. REMOVE 4TH GEAR NEEDLE ROLLER BEARING
(a) Remove the 4th gear needle roller bearing from the input shaft.
3. REMOVE 2ND SYNCHRONIZER OUTER RING
(a) Remove the 2nd synchronizer outer ring (No. 4 synchronizer ring) from the No. 2 transmission clutch hub.
4. REMOVE 4TH GEAR BEARING SPACER
(a) Remove the 4th gear bearing spacer from the No. 2 transmission clutch hub.
5. REMOVE 3RD GEAR
(a) Using 2 screwdrivers and a hammer, remove the No. 2 clutch hub setting shaft snap ring from the input shaft.
HINT: Use a shop rag or a piece of cloth to keep the snap ring from flying.
(b) Using SST and a press, remove the No. 2 transmission clutch hub and 3rd gear from the input shaft.
SST 09950-00020
NOTICE: Do not overtighten the SST.
6. REMOVE 3RD GEAR NEEDLE ROLLER BEARING
(a) Remove the 3rd gear needle roller bearing from the input shaft.
7. REMOVE NO. 3 SYNCHRONIZER RING
(a) Remove the No. 3 synchronizer ring from the 3rd gear.
8. REMOVE NO. 2 TRANSMISSION HUB SLEEVE
(a) Remove the No. 2 transmission hub sleeve, 3 No. 2 synchromesh shifting keys, and 3 No. 2 synchromesh shifting key springs from the No. 2 transmission clutch hub.
HINT: Use a shop rag or a piece of cloth to keep the shifting keys and shifting key springs from flying.
9. REMOVE INPUT SHAFT FRONT BEARING
(a) Using SST and a press, remove the input shaft front bearing (inner race) from the input shaft.
SST 09950-00020
NOTICE: Do not overtighten the SST.
INSPECTION
1. INSPECT 4TH GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the 4th gear thrust clearance.
Standard clearance: 0.10 to 0.57 mm (0.0039 to 0.0224 inch)
If clearance is out of specification, replace the No. 2 transmission clutch hub, 4th gear, or input shaft rear radial ball bearing.
2. INSPECT 3RD GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 3rd gear thrust clearance.
Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 inch)
If clearance is out of specification, replace the No. 2 transmission clutch hub, 3rd gear, or input shaft.
3. INSPECT 4TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 4th gear radial clearance.
Standard clearance mm (inch):
If clearance is out of specification, replace the 4th gear, needle roller bearing, or input shaft.
4. INSPECT 3RD GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 3rd gear radial clearance.
Standard clearance mm (inch):
If clearance is out of specification, replace the 3rd gear, needle roller bearing, or input shaft.
5. INSPECT INPUT SHAFT
(a) Using a V-block and dial indicator, inspect the shaft for runout.
Maximum runout: 0.03 mm (0.0012 inch)
If runout exceeds the maximum, replace the input shaft.
(b) Using a micrometer, measure the outside diameter of the input shaft journal surface.
Outside diameter mm (inch):
If the outside diameter is less than the minimum, replace the input shaft.
6. INSPECT 4TH GEAR
(a) Using a cylinder gauge, measure the inside diameter of the 4th gear.
Inside diameter:
If the inside diameter exceeds the maximum, replace the 4th gear.
7. INSPECT 3RD GEAR
(a) Using a cylinder gauge, measure the inside diameter of the 3rd gear.
Inside diameter: mm (inch):
If the inside diameter exceeds the maximum, replace the 3rd gear.
8. INSPECT 2ND SYNCHRONIZER OUTER RING
(a) Coat the 4th gear cone with gear oil. Turn the 2nd synchronizer outer ring (No. 4 synchronizer ring) in one direction while pushing it against the 4th gear cone. Check that the ring locks.
If the 2nd synchronizer outer ring does not lock, replace the ring or the 4th gear.
(b) Using a feeler gauge, measure the clearance between the synchronizer outer ring (No. 4 synchronizer ring) back and 4th gear spline end.
Standard clearance: 0.75 to 1.65 mm (0.0295 to 0.0650 inch)
If clearance is out of specification, replace the synchronizer ring.
9. INSPECT NO. 3 SYNCHRONIZER RING
(a) Coat the 3rd gear cone with gear oil. Turn the synchronizer outer ring in one direction while pushing it against the 3rd gear cone. Check that the ring locks.
If the synchronizer outer ring does not lock, replace the ring or the 3rd gear.
(b) Using a feeler gauge, measure the clearance between the No. 3 synchronizer ring back and 3rd gear spline end.
Standard clearance: 0.65 to 1.75 mm (0.0256 to 0.0689 inch)
If clearance is out of specification, replace the No. 3 synchronizer ring.
10. INSPECT NO. 2 TRANSMISSION HUB SLEEVE
(a) Inspect the sliding condition between the No. 2 transmission hub sleeve and No. 2 transmission clutch hub.
(b) Inspect the tip of the spline gear on the No. 2 transmission hub sleeve for wear.
If any defects are found, replace the transmission hub sleeve or the transmission clutch hub.
(c) Using vernier calipers, measure the width of the No. 3 transmission hub sleeve groove and the thickness of the claw part on the No. 1 gear shift fork, and calculate the clearance.
Standard clearance: 0.11 to 0.69 mm (0.0043 to 0.0272 inch) {A - B}
If clearance is out of specification, replace the No. 2 transmission hub sleeve and No. 2 gear shift fork with new ones.
REASSEMBLY
1. INSTALL INPUT SHAFT FRONT BEARING
(a) Using SST and a press, install the input shaft front bearing (inner race).
SST 09608-00071
2. INSTALL NO. 2 TRANSMISSION HUB SLEEVE
(a) Coat the transmission No. 2 hub sleeve with gear oil.
(b) Install the 3 synchromesh key springs with the No. 2 transmission hub sleeve.
NOTICE: Install the No. 2 transmission clutch hub sleeve and the No. 2 transmission clutch hub in the correct direction.
(c) Using a screwdriver, install the synchromesh shifting key to the input shaft.
3. INSTALL 3RD GEAR NEEDLE ROLLER BEARING
(a) Coat the 3rd gear bearing with gear oil and install it to the input shaft.
4. INSTALL 3RD GEAR
(a) Coat the 3rd gear with gear oil and install it to the input shaft.
5. INSTALL NO. 3 SYNCHRONIZER RING
(a) Coat the No. 3 synchronizer ring with gear oil and install it to the 3rd gear.
6. INSTALL NO. 2 TRANSMISSION CLUTCH HUB
(a) Using SST and a press, install the No. 2 transmission clutch hub to the input shaft.
SST 09316-60011 (09316-00041)
NOTICE:
^ Align the claw of the clutch hub No. 2 with the notch of the synchronizer ring No. 3.
^ Make sure that the 3rd gear can rotate.
(b) Select a snap ring so that clearance between the No. 2 transmission clutch hub and the No. 2 clutch hub shaft snap ring will be within the specified range. Using a brass bar and a hammer, install the snap ring.
Snap ring thickness (Part 1):
Snap ring thickness (Part 2):
7. INSTALL 4TH GEAR BEARING SPACER
(a) Coat the 4th gear bearing spacer with gear oil and install it to the input shaft.
8. INSTALL 2ND SYNCHRONIZER OUTER RING
(a) Coat the 2nd synchronizer outer ring (No. 4 synchronizer ring) with gear oil and install it to the No. 2 transmission clutch hub.
NOTICE: Align the claw of the No. 2 clutch hub with the notch of the 2nd synchronizer outer ring (No. 4 synchronizer ring).
9. INSTALL 4TH GEAR NEEDLE ROLLER BEARING
(a) Coat the 4th gear needle roller bearing with gear oil and install it to the input shaft.
10. INSTALL 4TH GEAR
(a) Coat the 4th gear with gear oil and install it to the input shaft.
11. INSTALL INPUT SHAFT REAR RADIAL BALL BEARING
(a) Using SST and a press, install the input shaft rear radial ball bearing to the input shaft.
SST 09608-06041
NOTICE:
^ Install the bearing with its groove facing rearward.
^ Make sure that the 3rd gear rotates.
(b) Select a snap ring so that the clearance between the input shaft radial ball rear bearing and the input shaft rear bearing snap ring will be within the specified range. Using a brass bar and a hammer, install the snap ring.
Snap ring:
