Input Shaft ASSY (C60): Overhaul

1. Using a feeler gauge, measure the 4th gear thrust clearance.
   1. Standard clearance: 0.10 - 0.55 mm (0.0039 - 0.0217 in.) 

Fig 1: Measuring 4th Gear Thrust Clearance

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1. Using a dial indicator, measure the 3rd gear thrust clearance.

   Standard clearance: 0.10 - 0.35 mm (0.0039 - 0.0138 in.) 

Fig 2: Measuring 3rd Gear Thrust Clearance

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1. Using a dial indicator, measure the 4th gear radial clearance.

Fig 3: Standard Clearance Specifications

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Standard clearance: 

Fig 4: Measuring 4th Gear Radial Clearance

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If the clearance is out of specification, replace the 4th gear needle roller bearing.

1. Using a dial indicator, measure the 3rd gear radial clearance.

Fig 5: Standard Clearance Specifications

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Standard clearance: 

Fig 6: Measuring 3rd Gear Radial Clearance

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If the clearance is out of specification, replace the 3rd gear needle roller bearing.

1. Using 2 screwdrivers and a hammer, remove the input shaft bearing shaft snap ring.
   NOTE: Using a waste to prevent the snap ring from the being scattered.
   Fig 7: Removing Input Shaft Bearing Shaft Snap Ring

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2. Using SST and a press, remove the input shaft bearing with 4th gear from the input shaft.

   SST 09950-00020

Fig 8: Removing 4th Gear

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1. Remove the 4th gear needle roller bearing and 4th gear bearing spacer from the input shaft.

Fig 9: Removing 4th Gear Needle Roller Bearing

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1. Remove the 4th gear synchronizer ring from the transmission clutch hub No. 2.

Fig 10: Removing 4th Gear Synchronizer Ring

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1. Using 2 screwdrivers and a hammer, remove the clutch hub No. 2 shaft snap ring from the input shaft.
   NOTE: Using a waste to prevent the snap ring from the being scattered.
   Fig 11: Removing Clutch Hub No. 2 Shaft Snap Ring

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2. Using SST and a press, remove the transmission clutch hub No. 2 with 3rd gear from the input shaft.

   SST 09950-00020

Fig 12: Removing Transmission Clutch Hub No. 2 With 3rd Gear From Input Shaft

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1. Remove the 3rd gear synchronizer ring from the 3rd gear.

Fig 13: Removing 3rd Gear Synchronizer Ring

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1. Remove the 3rd gear needle roller bearing from the input shaft.

Fig 14: Removing 3rd Gear Needle Roller Bearing

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1. Remove the transmission hub sleeve No. 2, 3 synchromesh shifting keys and 3 transmission shifting key springs from the transmission clutch hub No. 2.

Fig 15: Removing Transmission Hub Sleeve No. 2

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1. Using a dial indicator and 2 V-blocks, measure the shaft runout.
   1. Maximum runout: 0.015 mm (0.006 in.) 

   If the run out is exceeds the maximum, replace the input shaft.

   Fig 16: Measuring Shaft Runout

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2. Using a micrometer, measure the outer diameter of the input shaft journal surface.

Fig 17: Input Shaft Outer Diameter Specifications

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Outer diameter: 

Fig 18: Measuring Outer Diameter Of Input Shaft Journal Surface

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If the outer diameter is less than the minimum, replace the input shaft.

1. Using a cylinder gauge, measure the inside diameter of the 4th gear.

Fig 19: 4th Gear Inside Diameter Specifications

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Inside diameter: 

Fig 20: Measuring Inside Diameter Of 4th Gear

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If the inside diameter is exceeds the maximum, replace the 4th gear.

1. Using a cylinder gauge, measure the inside diameter of the 3rd gear.

Fig 21: 3rd Gear Inside diameter Specifications

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Inside diameter: 

Fig 22: Measuring Inside Diameter Of 3rd Gear

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If the inside diameter is exceeds the maximum, replace the 4th gear.

1. Coat the 4th gear cone with gear oil. Check the braking effect of the 4th gear synchronizer ring.
   Fig 23: Inspecting 4th Gear Synchronizer Ring

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2. Using a feeler gauge, measure the clearance between the 4th gear synchronizer ring back and 4th gear spline end.
   1. Standard clearance: 0.75 - 1.65 mm (0.0295 - 0.0650 in.) 

Fig 24: Measuring Clearance Between 4th Gear Synchronizer Ring Back And 4th Gear Spline End

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If the clearance is out of specification, replace the 4th gear synchronizer ring.

1. Coat the 3rd gear cone with gear oil. Check the braking effect of the 3rd gear synchronizer ring.
   Fig 25: Inspecting 3rd Gear Synchronizer Ring

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2. Using a feeler gauge, measure the clearance between the 3rd gear synchronizer ring back and 3rd gear spline end.
   1. Standard clearance: 0.65 - 1.75 mm (0.0256 - 0.0689 in.) 

Fig 26: Measuring Clearance Between 3rd Gear Synchronizer Ring Back And 3rd Gear Spline End

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If the clearance is out of specification, replace the 3rd gear synchronizer ring.

1. Check the sliding condition between the transmission hub No. 2 and transmission hub sleeve No. 2.
2. Check that the spline gear's edges of the transmission hub sleeve No. 2 is not worn down.
   Fig 27: Inspecting Transmission Hub Sleeve No. 2

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3. Using a vernier calipers, inspect the transmission hub sleeve No. 2 and gear shift fork No. 2 as shown in Fig 28 .
   1. Standard clearance: 0.15 - 0.35 mm (0.0059 - 0.0138 in.) 

Fig 28: Inspecting Transmission Hub Sleeve No. 2 And Gear Shift Fork No. 2

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If the clearance is out of specification, replace the transmission hub sleeve No. 2 and gear shift fork No. 2.

1. Coat the transmission hub sleeve No. 2 with gear oil, install it to the transmission clutch hub No. 2.
   NOTE: Do not set the transmission hub sleeve No. 2 and the transmission clutch hub No. 2 in incorrect orientation.
2. Using a screwdriver, install the 3 synchromesh shifting key springs with 3 synchromesh shifting keys.

Fig 29: Installing Transmission Hub Sleeve No. 2

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

Fig 30: Installing 3rd Gear Needle Roller Bearing

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

Fig 31: Installing 3rd Gear

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1. Coat the 3rd gear synchronizer ring with gear oil, install it to the 3rd gear.

Fig 32: Installing 3rd Gear Synchronizer Ring

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

   SST 09309-36100 (09309-03610), 09950-60010 (09951-00450)

   Fig 33: Installing Transmission Clutch Hub No. 2

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2. Select a snap ring that will allow minimum axial play.
   1. Standard clearance:0.1 mm (0.004 in.) or less 
   Fig 34: Snap Ring Thickness Specifications

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   Snap ring thickness: 

   Fig 35: Installing Snap Ring To Input Shaft

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3. Using a brass bar and a hammer, install the snap ring to the input shaft.

1. Coat the 4th gear synchronizer ring with gear oil, install it to the transmission clutch hub No. 2.

Fig 36: Installing 4th Gear Synchronizer Ring

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

Fig 37: Installing 4th Gear Needle Roller Bearing

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

Fig 38: Installing 4th Gear

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

   SST 09608-04031

   Fig 39: Installing Input Shaft Bearing

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2. Select a snap ring that will allow minimum axial play.
   1. Standard clearance:0.1 mm (0.004 in.) or less 
   Fig 40: Snap Ring Thickness Specifications

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   Snap ring thickness: 

   Fig 41: Installing Snap Ring To Input Shaft

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3. Using a brass bar and a hammer, install the snap ring to the input shaft.

1. Using a dial indicator, measure the 3rd gear radial clearance.

Fig 42: 3rd Gear Radial Clearance Specifications

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Standard clearance: 

Fig 43: Measuring 3rd Gear Radial Clearance

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If the clearance is out of specification, replace the 3rd gear needle roller bearing.

1. Using a dial indicator, measure the 4th gear radial clearance.

Fig 44: 4th Gear Radial Clearance Specifications

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Standard clearance: 

Fig 45: Measuring 4th Gear Radial Clearance

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If the clearance is out of specification, replace the 4th gear needle roller bearing.

1. Using a dial indicator, measure the 3rd gear thrust clearance.
   1. Standard clearance:0.10 - 0.35 mm (0.0039 - 0.0138 in.) 

Fig 46: Measuring 3rd Gear Thrust Clearance

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1. Using a feeler gauge, measure the 4th gear thrust clearance.
   1. Standard clearance:0.10 - 0.55 mm (0.0039 - 0.0217 in.) 

Fig 47: Measuring 4th Gear Thrust Clearance

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