Reassembly
RA61F MANUAL TRANSMISSION: INPUT SHAFT: REASSEMBLY
1. INSTALL INPUT SHAFT FRONT BEARING
(a) Using SST and a press, install the input shaft front bearing onto the input shaft.
SST : 09950-00020
HINT
Make sure that the groove of the bearing faces the correct direction as shown in the illustration.
2. INSTALL INPUT SHAFT FRONT BEARING SNAP RING
(a) Select a snap ring that will allow minimum axial play.
Standard clearance:
0.1 mm (0.004 in.) or less
Snap ring thickness:
(b) Using a brass bar and hammer, install the snap ring onto the input shaft.
3. INSTALL NO. 2 TRANSMISSION CLUTCH HUB
(a) Apply a light coat of gear oil to the sleeve and hub.
(b) Install the clutch hub sleeve onto the No. 2 clutch hub.
(c) Put the ball into the keyhole from the bottom.(*1)
(d) Put the spring under the ball.(*2)
(e) Insert the ball and spring into the No. 2 clutch hub while attached onto the key.(*3)
NOTICE:
Prevent the ball from flying off.
HINT
* Perform the same procedure (*1 through *3) for all the 3 portions.
* Make sure that the No. 2 clutch hub faces the correct direction as shown in the illustration.
4. INSTALL NO. 3 TRANSMISSION CLUTCH HUB
(a) Apply a light coat of gear oil to the sleeve and hub.
(b) Install the clutch hub sleeve onto the No. 3 clutch hub.
(c) Put the ball into the keyhole from the bottom.(*1)
(d) Put the spring under the ball.(*2)
(e) Insert the ball and spring into the No. 3 clutch hub while attached onto the key.(*3)
NOTICE:
Prevent the ball from flying off.
HINT
* Perform the same procedure (*1 through *3) for all the 3 portions.
* Make sure that the No. 3 clutch hub faces the correct direction as shown in the illustration.
5. INSTALL 4TH GEAR NEEDLE ROLLER BEARING
(a) Coat the 4th gear needle roller bearing with gear oil, then install it onto the input shaft.
6. INSTALL 4TH GEAR
(a) Coat the 4th gear and No. 3 synchronizer ring with gear oil, then install them onto the input shaft.
(b) Using SST and a press, install the No. 2 clutch hub onto the input shaft.
SST : 09308-14010
HINT
Align the convex portion of the synchronizer ring with the groove of the clutch hub.
(c) Install the clutch hub and confirm that the gear and synchronizer ring move smoothly.
7. INSTALL CLUTCH HUB NO.2 SETTING SHAFT SNAP RING
(a) Select a snap ring that will allow minimum axial play.
Standard clearance:
0.1 mm (0.004 in.) or less
Snap ring thickness:
(b) Using a snap ring expander, install the snap ring onto the input shaft.
8. INSTALL NO. 2 SYNCHRONIZER RING SET
(a) Coat the No. 2 synchronizer ring set with gear oil, then install it onto the input shaft.
9. INSTALL SPACER
(a) Coat the spacer with gear oil, and install it onto the input shaft.
10. INSTALL 3RD GEAR NEEDLE ROLLER BEARING
(a) Coat the 3rd gear needle roller bearing with gear oil, and install it onto the input shaft.
11. INSTALL STRAIGHT PIN
(a) Install the straight pin into the input shaft.
12. INSTALL 3RD GEAR
(a) Coat the 3rd gear with gear oil, and install it onto the input shaft.
13. INSTALL 3RD GEAR THRUST WASHER
(a) Coat the 3rd gear thrust washer with gear oil, and install it onto the input shaft.
HINT
Align the straight pin with the groove of the gear thrust washer and install it.
14. INSTALL GEAR THRUST WASHER SHAFT SNAP RING
(a) Select a snap ring that will allow minimum axial play.
Standard clearance:
0.1 mm (0.004 in.) or less
Snap ring thickness:
(b) Using a snap ring expander, install the snap ring onto the input shaft.
15. INSTALL SHAFT SNAP RING
(a) Coat the shaft snap ring with gear oil, and install it onto the input shaft.
16. INSTALL 6TH GEAR NEEDLE ROLLER BEARING
(a) Coat the 6th gear needle roller bearing with gear oil, and install it onto the input shaft.
17. INSTALL 6TH GEAR
(a) Install the 6th gear onto the input shaft.
(b) Install the synchronizer ring onto the input shaft.
(c) Using SST and a press, install the clutch hub onto the input shaft.
SST : 09309-37010
SST : 09950-00020
(d) Install the clutch hub and confirm that the gear and synchronizer ring move smoothly.
18. INSTALL TRANSMISSION CLUTCH HUB NO.3 SHAFT SNAP RING
(a) Select a snap ring that will allow minimum axial play.
Standard clearance:
0.1 mm (0.004 in.) or less
Snap ring thickness:
(b) Using a brass bar and a hammer, install the snap ring onto the input shaft.
19. INSPECT 6TH GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 6th gear thrust clearance.
Standard clearance:
0.20 to 0.49 mm (0.0079 to 0.0193 in.)
If the clearance is outside the specification, replace the defective gear, spacer or shaft.
20. INSPECT 3RD GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the 3rd gear thrust clearance.
Standard clearance:
0.09 to 0.52 mm (0.0035 to 0.0205 in.)
If the clearance is outside the specification, replace the defective gear, thrust washer, clutch hub or shaft.
21. INSPECT 4TH GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 4th gear thrust clearance.
Standard clearance:
0.12 to 0.38 mm (0.0047 to 0.0150 in.)
If the clearance is outside the specification, replace the defective gear, clutch hub or shaft.
22. INSPECT 6TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 6th gear radial clearance.
Standard clearance:
0.015 to 0.065 mm (0.0006 to 0.0026 in.)
If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.
23. INSPECT 3RD GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 3rd gear radial clearance.
Standard clearance:
0.015 to 0.067 mm (0.0006 to 0.0026 in.)
If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.
24. INSPECT 4TH GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 4th gear radial clearance.
Standard clearance:
0.015 to 0.067 mm (0.0006 to 0.0026 in.)
If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.