Assembly of Input Shaft Assembly

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




1. INSPECT NO.2 CLUTCH HUB INTO HUB SLEEVE
a. Install the spring and shifting keys to the clutch hub.
b. Install the hub sleeve to the clutch hub.




2. INSTALL NEEDLE ROLLER BEARING, THIRD GEAR, SYNCHRONIZER RINGS AND NO.2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT
a. Apply MP grease to the needle roller bearing.
b. Assembly 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




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 - 0.35 mm (0.0039 - 0.0138 in.)




5. INSTALL SPACER, SYNCHRONIZER RING, NEEDLE ROLLER BEARINGS, FOURTH 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




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 the 4th gear thrust clearance.

Standard clearance: 0.10 - 0.55 mm (0.0039 - 0.0217 in.)