Assembly of Input Shaft Assembly
ASSEMBLY OF INPUT SHAFT ASSEMBLYHINT: Coat all the sliding and rotating surface with gear oil before assembly.
1. INSERT NO.2 CLUTCH HUB SLEEVE
a. Install the clutch hub and shifting keys to the hub sleeve.
b. Install the shifting key springs under the shifting keys.
NOTE: Install the key springs positioned so that their end gaps are not in line.
2. INSTALL NEEDLE ROLLER BEARING, THIRD GEAR, SYNCHRONIZER RING AND NO.2 HUB SLEEVE ASSEMBLY TO INPUT SHAFT
a. Apply MP grease to the needle roller bearings.
b. Install the 3rd gear.
c. Place the synchronizer ring 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 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.)
8. INSTALL INPUT SHAFT FRONT BEARING INNER RACE
Using SST and a press, install the input shaft front bearing inner race.
SST 09316-60010 (09316-00020)