Installation

INPUT SHAFT

Input Shaft / <F5M51> 3.0L:

ASSEMBLY SERVICE POINTS






>> A <<
OIL SEAL INSTALLATION
Install the oil seal into the illustrated position of the input shaft.







>> B <<
BALL BEARING INSTALLATION
1. Using special tool MID99880, support the 2nd speed gear portion of the input shaft, and then set them on the press,
2. Using special tools MD998812, MD99881, and MD998816, press install the bearing with the press.







>> C <<
SNAP RING INSTALLATION
1. Install the thickest snap ring that can be fitted in the snap ring groove of input shaft.
2. Make sure that the ball bearing end play meets the standard value.:

Standard value:..................0 - 0.12 mm (0 - 0.0047 inch)











>> D <<
SYNCHRONIZER SPRING INSTALLATION
Install the synchronizer spring to the illustrated position of the synchronizer ring and outer synchronizer ring .



>> E <<
SYNCHRONIZER RING INSTALLATION

CAUTION: There are 3rd speed and 4th speed synchronizer rings, if the wrong one is installed it will effect the shift feeling.

1. Ascertain whether or not there are identification notches on the synchronizer ring.
Two notches: 3rd speed synchronizer ring
No notches: 4th speed synchronizer ring
2. Install the synchronizer ring so that it does not angle to the cone of the gear.

>> F <<
3RD-4TH SPEED SYNCHRONIZER HUB INSTALLATION
1. Using special tool MD998801, support the 2nd speed gear portion of the input shaft, and then set them on the press.
2. Make sure that the synchronizer ring or inner synchronizer ring has been perfectly matched to the 3rd speed gear cone.
3. Check the installation direction of the 3rd-4th speed synchronizer hub, and put It on the input shaft.
4. Using special tools MD998812, MD99881, and MD998825, press install the 3rd-4th speed synchronizer hub with the press.

5. Make sure that the synchronizer ring or outer synchronizer ring can rotate freely.

>> G <<
SYNCHRONIZER SLEEVE INSTALLATION
1. Check the installation direction of the synchronizer sleeve, and install it onto the 3rd-4th speed synchronizer hub.

2. Install the synchronizer sleeve so that the areas with teeth that have raised tips (three areas total) are aligned with the areas on the synchronizer hub that have deep grooves between the teeth (three areas total).

>> H <<
4TH SPEED GEAR SLEEVE INSTALLATION
1. Using special tool MD998801, support the 2nd speed gear I portion of the;input shaft, and then set them on the press.

2. Using special tools MD998812, MD998813, MD998824 and MD998825 , press install the 4th speed gear sleeve with the press.

>> I <<
5TH SPEED GEAR INSTALLATION
1. Using special tool MD998801, support the 2nd speed gear portion of the input shaft, and then set them on the press.
2. Using special tools MD998812, MD998813, MD998824 and MD998825 , press install the 5th speed gear in the input shaft.

>> J <<
THRUST PLATE INSTALLATION
1. Install the thickest thrust plates that can be fitted in the groove of input shaft. Install the thrust plate so the surface stamped with the identification mark is facing up.
2. Make sure that the 5th speed gear end play meets the standard value.

Standard value:...........0 - .0.09 mm (0 - 0.0035 inch)

>> K <<
THRUST PLATE STOPPER INSTALLATION
Install the thrust plate stopper by pressing special tools MD998813, MD998824 and MD998825 by hand. Make sure that it is not tilted.

>> L <<
BALL BEARING INSTALLATION
1. Using special tool MD998801, support the 2nd speed gear portion of the input shaft, and then set them on the press.
2. Using special tools MD99881, and MD998818, press install the ball bearing in the input shaft.

>> M <<
SNAP RING INSTALLATION


1. Install the thickest snap ring that can be fitted in the groove of input shaft.
2. Make sure that the ball bearing end play meet the standard value.

Standard value:...............0 - 0.12 mm (0 - 0.0047 Inch)