Input Shaft Reassembly

Reference: INPUT SHAFT DISASSEMBLY 

Reference: INPUT SHAFT INSPECTION 

1. Clean all components thoroughly, inspect them for any abnormality and replace with new ones as necessary.
2. To ensure lubrication, air blow oil holes (1) and make sure that they are free from any obstruction.
   Fig 1: Identifying Lubrication Oil Holes

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3. Drive in input shaft front bearing (1) to input shaft using special tool and hammer and then install snap ring in specified direction as shown in figure.

   Special Tool 

   1. 09940-51710 
   NOTE: Input shaft front bearing circlip (2) must be installed before input shaft front bearing is installed.
   Fig 2: Identifying Special Tool On Input Shaft Front Bearing

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4. Apply oil to high speed gear needle bearing (5), and then install needle bearing, 4th gear (5) and high speed synchronizer ring (7) to input shaft.
5. Assemble synchronizer sleeve (4) and hub (3) as follows.
   1. Fit high speed synchronizer sleeve to hub in specified direction as shown in figure.
   2. Insert 3 keys (2) to hub.
   3. Set springs (1) at specified position as shown in figure.

   Synchronizer key installation position 

   : A = B 

   Fig 3: Identifying Synchronizer Key Installation Position

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6. Drive in high speed synchronizer assembly (1) using special tool and hammer.
   NOTE:

   • While press-fitting sleeve & hub, make sure that synchronizer ring key slots (2) are aligned with keys in sleeve & hub assembly.
   • Check free rotation of 4th gear after press fitting sleeve & hub assembly.

   Special Tool 

   1. 09913-84510 
      Fig 4: Identifying Special Tool On High Speed Synchronizer Assembly

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7. Check 4th gear (1) thrust clearance by using thickness gauge. If clearance is out of specification, repress-fit or replace defective part.

   4th gear thrust clearance 

   "a": 0.10-0.30 mm (0.004-0.012 in.) 

   Fig 5: Identifying 4th Gear Thrust Clearance

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8. Apply oil to high speed gear needle bearing, and then install 3rd gear bush (1), high speed gear needle bearing (2) and 3rd gear (3).
   Fig 6: Identifying 3rd Gear Bush, High Speed Gear Needle Bearing & 3rd Gear

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9. Press-fit 5th speed synchronizer hub (1) using special tool and hammer.

   Special Tool 

   1. 09913-84510 
      Fig 7: Identifying Special Tool On 5th Speed Synchronizer Hub

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10. Check 3rd gear (1) thrust clearance by using thickness gauge. If clearance is out of specification, repress-fit or replace defective part.

    3rd gear thrust clearance 

    "a": 0.10-0.30 mm (0.004-0.012 in.) 

    Fig 8: Identifying 3rd Gear Thrust Clearance

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11. Tighten input shaft 5th hub nut to specified torque in the same manner as step  4) of Input Shaft Disassembly  .
    CAUTION: Do not hold spline, gear teeth or abrasive surface of shaft with vise through "V" blocks or the like, otherwise shaft components may be damaged.

    Tightening torque 

    Input shaft 5th hub nut: 210 N.m (21.0 kg-m, 152.0 lb-ft) 

12. Caulk input shaft 5th hub nut (2) using caulking tool.
13. Drive in new input shaft union (1) using puller and hydraulic press.
    Fig 9: Identifying Special Tool On Input Shaft 5th Hub Nut

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