Reassembly

C50 MANUAL TRANSAXLE: INPUT SHAFT: REASSEMBLY

1. INSTALL NO. 2 TRANSMISSION HUB SLEEVE

(a) Coat the No. 2 transmission hub sleeve with gear oil, and install it onto the No. 2 transmission clutch hub.

NOTICE:
Orient the No. 2 transmission hub sleeve and No. 2 transmission clutch hub correctly.

(b) Using a screwdriver, install the 3 synchromesh key springs with 3 synchromesh shifting keys onto the No. 2 transmission clutch hub.

2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING

(a) Coat the 3rd gear needle roller bearing with gear oil and install it onto the input shaft.

3. INSTALL 3RD GEAR

(a) Coat the 3rd gear with gear oil and install it onto the input shaft.

4. INSTALL 3RD GEAR SYNCHRONIZER RING

(a) Coat the 3rd gear synchronizer ring with gear oil and install it onto the 3rd gear.

5. INSTALL NO. 2 TRANSMISSION CLUTCH HUB

(a) Using SST and a press, install the No. 2 transmission clutch hub onto the input shaft.

SST : 09316-60011

09316-00021

NOTICE:
Fit the synchromesh shifting key into the groove of the synchronizer ring correctly.

(b) Select a snap ring that will allow minimum axial play.

Standard clearance:

0.1 mm (0.0039 in.) or less

Snap ring thickness:

(a) Coat the 4th gear synchronizer ring with gear oil and install it onto the No. 2 transmission clutch hub.

7. INSTALL 4TH GEAR NEEDLE ROLLER BEARING

(a) Coat the 4th gear needle roller bearing and 4th gear bearing spacer with gear oil and install them onto the No. 2 transmission clutch hub.

8. INSTALL 4TH GEAR

(a) Coat the 4th gear with gear oil and install it onto the input shaft.

9. INSTALL INPUT SHAFT REAR RADIAL BALL BEARING

(a) Using SST and a press, install the input shaft rear radial ball bearing onto the input shaft.

SST : 09608-04031

(b) Select a snap ring that will allow minimum axial play.

Standard clearance:

0.1 mm (0.0039 in.) or less

Snap ring thickness:

(c) Using a brass bar and a hammer, install the snap ring onto the input shaft.

NOTICE:
Do not damage the journal surface of the snap ring.

10. INSPECT 3RD GEAR RADIAL CLEARANCE

(a) Using a dial gauge, measure the 3rd gear radial clearance.

Standard clearance:

JTEKT made
0.015 to 0.058 mm (0.0006 to 0.0023 in.)

NSK made
0.015 to 0.056 mm (0.0006 to 0.0022 in.)

Maximum clearance:

JTEKT made
0.058 mm (0.0023 in.)

NSK made
0.056 mm (0.0022 in.)

If the clearance exceeds the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft.

11. INSPECT 4TH GEAR RADIAL CLEARANCE

(a) Using a dial gauge, measure the 4th gear radial clearance.

Standard clearance:

0.009 to 0.050 mm (0.0004 to 0.0020 in.)

Maximum clearance:

0.050 mm (0.0020 in.)

If the clearance exceeds the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft.

12. INSPECT 3RD GEAR THRUST CLEARANCE

(a) Using a dial gauge, measure the 3rd gear thrust clearance.

Standard clearance:

0.1 to 0.35 mm (0.0039 to 0.0138 in.)

Maximum clearance:

0.35 mm (0.0138 in.)

If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 3rd gear or input shaft.

13. INSPECT 4TH GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the 4th gear thrust clearance.

Standard clearance:

0.1 to 0.55 mm (0.0039 to 0.0217 in.)

Maximum clearance:

0.55 mm (0.0217 in.)

If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 4th gear or input shaft rear radial ball bearing.