Input Shaft ASSY

INPUT SHAFT ASSY
OVERHAUL
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 transmission clutch hub No.2, 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 transmission clutch hub No.2, 3rd gear or input shaft.
3. INSPECT 4TH GEAR RADIAL CLEARANCE

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

Standard clearance

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

If clearance is out of specification, replace the 3rd gear, needle roller bearing or input shaft.
5. REMOVE 4TH GEAR

a) Hold the input shaft assy in a vise with soft jaws.
b) Using 2 screwdrivers and a hammer, remove the input shaft rear bearing shaft snap ring from the input shaft.

NOTICE: Use a shop rag 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.

6. REMOVE 4TH GEAR NEEDLE ROLLER BEARING

a) Remove the 4th gear needle roller bearing from the input shaft.
7. REMOVE 2ND SYNCHRONIZER OUTER RING

a) Remove the 2nd synchronizer outer ring (synchronizer ring No.4) from the transmission clutch hub No.2.
8. REMOVE 4TH GEAR BEARING SPACER

a) Remove the 4th gear bearing spacer from the transmission clutch hub No.2.
9. REMOVE 3RD GEAR

a) Using 2 screwdrivers and a hammer, remove the clutch hub No.2 setting shaft snap ring from the input shaft.

NOTICE: Use a shop rag to keep the snap ring from flying.

b) Using SST and a press, remove the transmission clutch hub No.2 and 3rd gear from the input shaft.
SST 09950-00020

NOTICE: Do not overtighten the SST.

10. REMOVE 3RD GEAR NEEDLE ROLLER BEARING

a) Remove the 3rd gear needle roller bearing from the input shaft.
11. REMOVE SYNCHRONIZER RING NO.3

a) Remove the synchronizer ring No.3 from the 3rd gear.
12. REMOVE TRANSMISSION HUB SLEEVE NO.2

a) Remove the transmission hub sleeve No.2, 3 synchromesh shifting key No.2 and 3 synchromesh shifting key spring No.2 from the transmission clutch hub No.2.

NOTICE: Cover with a shop rag to keep the shifting key and shifting key spring from flying.

13. REMOVE INPUT SHAFT FRONT BEARING

a) Using SST and a press, remove the input shaft bearing front (inner race) from the input shaft.
SST 09950-00020

NOTICE: Do not overtighten the SST.

14. INSPECT INPUT SHAFT

a) Using a V-block and dial indicator, inspect the shaft for run out.
Maximum run out: 0.03 mm (0.0012 inch)
If run out exceeds the maximum, replace the input shaft.

b) Using a micrometer, measure the outside diameter of the input shaft journal surface.

Outside diameter

If the outside diameter is less than the minimum, replace the input shaft.
15. 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.
16. INSPECT 3RD GEAR

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

Inside diameter

If the inside diameter exceeds the maximum, replace the 3rd gear.
17. INSPECT 2ND SYNCHRONIZER OUTER RING

a) Coat the 4th gear cone with gear oil. Turn the 2nd synchronizer outer ring (synchronizer ring No.4) in one direction while pushing it against the 4th gear cone. Check that the ring locks.
If the 2rd 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 (synchronizer ring No.4) 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.
18. INSPECT SYNCHRONIZER RING NO.3

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 3th gear.

b) Using a feeler gauge, measure the clearance between the synchronizer ring No.3 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 synchronizer ring No.3.
19. INSPECT TRANSMISSION HUB SLEEVE NO.2

a) Inspect the sliding condition between the transmission hub sleeve No.2 and transmission clutch hub No.2.
b) Inspect the tip of the spline gear on the transmission hub sleeve No.2 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 transmission hub sleeve No.3 groove and the thickness of the claw part on the gear shift fork No.1, 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 transmission hub sleeve No.2 and gear shift fork No.2 with new ones.
20. INSTALL INPUT SHAFT FRONT BEARING

a) Using SST and a press, install the input shaft front bearing (inner race).
SST 09608-00071
21. INSTALL TRANSMISSION HUB SLEEVE NO.2

a) Coat the transmission hub sleeve No.2 with gear oil.
b) Install the 3 synchromesh key springs with the transmission hub sleeve No.2.

NOTICE: Install the transmission clutch hub sleeve No.2 and the transmission clutch hub No.2 in the correct direction.

c) Using a screwdriver, install the synchromesh shifting key to the input shaft.
22. INSTALL 3RD GEAR NEEDLE ROLLER BEARING

a) Coat the 3rd gear bearing with gear oil, and install it to the input shaft.
23. INSTALL 3RD GEAR

a) Coat the 3rd gear with gear oil, and install it to the input shaft.
24. INSTALL SYNCHRONIZER RING NO.3

a) Coat the synchronizer ring No.3 with gear oil, and install it to the 3rd gear.
25. INSTALL TRANSMISSION CLUTCH HUB NO.2

a) Using SST and a press, install the transmission clutch hub No.2 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 and install them.
^ Make sure that the 3rd gear can rotate.

b) Select a snap ring so that clearance between the transmission clutch hub No.2 and the clutch hub No.2 shaft snap ring will be within specification. Using a brass bar and a hammer, install the snap ring.
Standard clearance: 0.1 mm or less (0.0039 inch or less)

Snap ring thickness

26. INSTALL 4TH GEAR BEARING SPACER

a) Coat the 4th gear bearing spacer with gear oil, and install it to the input shaft.
27. INSTALL 2ND SYNCHRONIZER OUTER RING

a) Coat the 2nd synchronizer outer ring (synchronizer ring No.4) with gear oil, and install it to the transmission clutch hub No.2.

NOTICE: Align the claw of the clutch hub No.2 with the notch of the 2nd synchronizer outer ring (synchronizer ring No.4) and install.

28. INSTALL 4TH GEAR NEEDLE ROLLER BEARING

a) Coat the 4th gear needle roller bearing with gear oil, and install it to the input shaft.
29. INSTALL 4TH GEAR

a) Coat the 4th gear with gear oil, and install it to the input shaft.
30. 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.

NOTICE:
^ Install the bearing with its groove facing reward.
^ Make sure that the 3rd gear rotates.

SST 09608-06041

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 specification. Using a brass bar and a hammer, install the snap ring.
Standard clearance: 0.1 mm or less

Snap ring

31. INSPECT 3RD GEAR RADIAL CLEARANCE

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

Standard clearance

If clearance is out of specification, replace the 3rd gear, needle roller bearing or input shaft.
32. INSPECT 4TH GEAR RADIAL CLEARANCE

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

Standard clearance

If clearance is out of specification, replace the 4th gear, needle roller bearing or input shaft.
33. INSPECT 3RD GEAR THRUST CLEARANCE