ПЕРВИЧНЫЙ ВАЛ ПОВТОРНАЯ СБОРКА

PROCEDURE

  1. INSTALL FRONT INPUT SHAFT BEARING

    1. Using a press, install the front input shaft bearing to the input shaft.

      A012IP7
  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING

    1. Coat the 3rd gear needle roller bearing with gear oil and install it to the input shaft.

      A012IVE
  3. INSTALL 3RD GEAR

    1. Coat the 3rd gear with gear oil and install it to the input shaft.

      A012H3F
  4. INSTALL NO. 3 SYNCHRONIZER RING

    1. Coat the No. 3 synchronizer ring with gear oil and install it to the 3rd gear.

      A012I7S
  5. INSTALL NO. 2 TRANSMISSION CLUTCH HUB

    1. Coat the No. 2 transmission clutch hub with gear oil.

    2. Position the No. 2 transmission clutch hub to the input shaft.

      A012M1L
      Note:

      Position the No. 2 transmission clutch hub correctly as shown in the illustration.

    3. Using SST and a press, install the No. 2 transmission clutch hub to the input shaft.

      A012L51N10
      SST
      09527-21011
      09316-60011   ( 09316-00011 )
      Note:

      When installing the No. 2 transmission clutch hub, align the protrusion of the No. 3 synchronizer ring with the cutout of the No. 2 transmission clutch hub.

  6. INSTALL NO. 2 CLUTCH HUB SETTING SHAFT SNAP RING

    1. Select a No. 2 clutch hub setting shaft snap ring that will allow minimal axial play.

      Standard Clearance
      0.1 mm (0.00394 in.) or less
      No. 2 Clutch Hub Setting Shaft Snap Ring Thickness
      Mark Thickness mm (in.) Mark Thickness mm (in.)
      0 2.27 (0.0894) 4 2.47 (0.0972)
      1 2.32 (0.0913) 5 2.52 (0.0992)
      2 2.37 (0.0933) 6 2.57 (0.1012)
      3 2.42 (0.0953) 7 2.62 (0.1031)
    2. Using a snap ring expander, install the new No. 2 clutch hub setting shaft snap ring.

      A012ID9
      Note:
      • Be sure to properly install the snap ring because it easily expands.

      • Do not damage the journal surface of the snap ring.

  7. INSTALL NO. 2 SYNCHROMESH SHIFTING KEY

    1. Install the 3 No. 2 synchromesh shifting keys to the No. 2 transmission clutch hub.

      A012GJ0
  8. INSTALL NO. 2 TRANSMISSION HUB SLEEVE

    1. Coat the No. 2 transmission hub sleeve with gear oil.

    2. Install the No. 2 transmission clutch hub to the No. 2 transmission hub sleeve.

      A012H9UC03
      *a Align
      Note:

      When installing the No. 2 transmission hub sleeve, align the protrusion of the No. 2 transmission hub sleeve with the cutout of the No. 2 transmission clutch hub.

  9. INSTALL 4TH GEAR BEARING SPACER

    1. Install the 4th gear bearing spacer to the No. 2 transmission clutch hub.

      A012JFF
  10. INSTALL 4TH GEAR NEEDLE ROLLER BEARING

    1. Coat the 4th gear needle roller bearing and 4th gear bearing spacer with gear oil and install the 4th gear needle roller bearing to the input shaft.

      A012IEU
  11. INSTALL OUTER 2ND SYNCHRONIZER RING

    1. Coat the outer 2nd gear synchronizer ring with gear oil and install it to the No. 2 transmission clutch hub.

      A012FR3
      Note:

      When installing the outer 2nd synchronizer ring, align the protrusion of the outer 2nd synchronizer ring with the cutout of the No. 2 transmission clutch hub.

  12. INSTALL 4TH GEAR

    1. Coat the 4th gear with gear oil and install it to the input shaft.

      A012I0N
      Note:

      Install the 4th gear as shown in the illustration.

  13. INSTALL INNER 5TH GEAR BEARING RACE LOCK BALL

    1. Coat the inner 5th gear bearing race lock ball with gear oil and install it to the input shaft.

      A012F78
  14. INSTALL INNER 5TH GEAR BEARING RACE

    1. Coat the inner 5th gear bearing race with gear oil and install it to the input shaft.

      A012FIG
      Note:

      Align the groove of the inner 5th gear bearing race with the ball.

  15. INSTALL 5TH GEAR NEEDLE ROLLER BEARING

    1. Coat the 5th gear needle roller bearing and inner 5th gear bearing race with gear oil and install the inner 5th gear bearing race to the input shaft.

      A012KH5
  16. INSTALL 5TH GEAR

    1. Coat the 5th gear with gear oil and install it to the input shaft.

      A012JUE
      Note:

      Install the 5th gear as shown in the illustration.

  17. INSTALL NO. 5 SYNCHRONIZER RING (for 5th Gear)

    1. Coat the No. 5 synchronizer ring (for 5th gear) with gear oil and install it to the 5th gear.

      A012N6J
  18. INSTALL NO. 3 TRANSMISSION CLUTCH HUB

    1. Coat the No. 3 transmission clutch hub with gear oil.

    2. Install the No. 3 transmission clutch hub to the input shaft.

      A012N2F
      Note:

      Position the No. 3 transmission clutch hub correctly as shown in the illustration.

    3. Using SST and a press, install the No. 3 transmission clutch hub to the input shaft.

      A012MHLN10
      SST
      09309-37010
      09527-21011
      Note:

      When installing the No. 3 transmission clutch hub, align the protrusion of the No. 5 synchronizer ring with the cutout of the No. 3 transmission clutch hub.

  19. INSTALL NO. 3 SYNCHROMESH SHIFTING KEY

    1. Install the 3 No. 3 synchromesh shifting keys to the No. 3 transmission clutch hub.

      A012IX4
  20. INSTALL INNER 6TH GEAR BEARING RACE LOCK BALL

    1. Coat the inner 6th gear bearing race lock ball with gear oil and install it to the input shaft.

      A012M3R
  21. INSTALL NO. 3 TRANSMISSION HUB SLEEVE

    1. Coat the No. 3 transmission hub sleeve with gear oil.

    2. Install the No. 3 transmission hub sleeve to the No. 3 transmission clutch hub.

      A012LYE
      Note:

      Install the No. 3 transmission hub sleeve as shown in the illustration.

  22. INSTALL INNER 6TH GEAR BEARING RACE

    1. Coat the inner 6th gear bearing race with gear oil and install it to the input shaft.

      A012F2L
      Note:

      Align the groove of the inner 6th gear bearing race with the ball.

  23. INSTALL 6TH GEAR NEEDLE ROLLER BEARING

    1. Coat the 6th gear needle roller bearing and inner 6th gear bearing race with gear oil and install the 6th gear needle roller bearing to the input shaft.

      A012LE3
  24. INSTALL NO. 5 SYNCHRONIZER RING (for 6th Gear)

    1. Coat the No. 5 synchronizer ring (for 6th gear) with gear oil and install it to the No. 3 transmission clutch hub.

      A012I5F
      Note:

      When installing the No. 5 synchronizer ring, align the protrusion of the No. 5 synchronizer ring with the cutout of the No. 3 transmission clutch hub.

  25. INSTALL 6TH GEAR SUB-ASSEMBLY

    1. Coat the 6th gear sub-assembly with gear oil and install it to the input shaft.

      A012M5P
      Note:

      Install the 6th gear sub-assembly as shown in the illustration.

  26. INSTALL REAR INPUT SHAFT RADIAL BALL BEARING

    1. Using SST and a press, install the rear input shaft radial ball bearing to the input shaft.

      A012KG7N09
      SST
      09527-21011
      09608-04031
  27. INSTALL REAR INPUT SHAFT BEARING SHAFT SNAP RING

    1. Select a new snap ring that will allow minimal axial play.

      Standard Clearance
      0.1 mm (0.00394 in.) or less
      Rear Input Shaft Bearing Shaft Snap Ring Thickness
      Mark Thickness mm (in.) Mark Thickness mm (in.)
      A 1.65 (0.0649) H 2.00 (0.0787)
      B 1.70 (0.0669) J 2.05 (0.0807)
      C 1.75 (0.0689) K 2.10 (0.0827)
      D 1.80 (0.0709) L 2.15 (0.0846)
      E 1.85 (0.0728) M 2.20 (0.0866)
      F 1.90 (0.0748) N 2.25 (0.0886)
      G 1.95 (0.0768) P 2.30 (0.0906)
    2. Using a snap ring expander, install the new rear input shaft bearing shaft snap ring.

      A012I00
      Note:
      • Be sure to properly install the snap ring because it easily expands.

      • Do not damage the journal surface of the snap ring.

  28. INSPECT 3RD GEAR RADIAL CLEARANCE

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  29. INSPECT 4TH GEAR RADIAL CLEARANCE

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  30. INSPECT 5TH GEAR RADIAL CLEARANCE

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  31. INSPECT 6TH GEAR RADIAL CLEARANCE

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  32. INSPECT 3RD GEAR THRUST CLEARANCE

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  33. INSPECT 4TH GEAR THRUST CLEARANCE

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  34. INSPECT 5TH GEAR THRUST CLEARANCE

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  35. INSPECT 6TH GEAR THRUST CLEARANCE

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