41–38

MANUAL TRANSMISSION/TRANSAXLE – INPUT SHAFT ASSY (C250)

410DF–01

OVERHAUL

1. INSPECT 4TH GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the 4th gear thrust clear-
ance.
Standard clearance:
0.1 – 0.55 mm (0.0039 – 0.0217 in.)
Maximum clearance:
0.55 mm (0.0217 in.)

C80557

2. INSPECT 3RD GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the 3rd gear thrust clear-
ance.
Standard clearance:
0.1 – 0.35 mm (0.0039 – 0.0138 in.)
Maximum clearance:
0.35 mm (0.0138 in.)

C67816

3. INSPECT 4TH GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 4th gear radial clear-
ance between the gear and shaft.
Standard clearance:
0.015 – 0.058 mm (0.0006 – 0.0023 in.)
Maximum clearance:
0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the gear,
C80558 needle roller bearing or shaft.

4. INSPECT 3RD GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 3rd gear radial clear-
ance between the gear and shaft.
Standard clearance:
0.015 – 0.058 mm (0.0006 – 0.0023 in.)
Maximum clearance:
0.058 mm (0.0023 in.)
If the clearance exceeds the maximum, replace the gear,
C67815 needle roller bearing or shaft.

C250 M/T REPAIR MANUAL (RM1020E)

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MANUAL TRANSMISSION/TRANSAXLE – INPUT SHAFT ASSY (C250)

5. REMOVE 4TH GEAR

(a) Using 2 screwdrivers and a hammer, remove the input
shaft rear bearing shaft snap ring from input shaft.

C80559

(b) Using SST and a press, remove the input shaft radial ball
bearing rear and 4th gear from input shaft.
NOTICE:
SST Do not tighten SST excessively.
SST 09950–00020

Q04983

6. REMOVE 4TH GEAR NEEDLE ROLLER BEARING

(a) Remove the 4th gear needle roller bearing and 4th gear
bearing spacer from input shaft.

C80560

7. REMOVE SYNCHRONIZER RING NO.2 (FOR FOURTH

SYNCHRONIZER RING)
(a) Remove synchronizer ring No.2 from transmission clutch
hub No.2.

C80561

8. REMOVE 3RD GEAR

(a) Using 2 screwdrivers and a hammer, remove the clutch
hub No.2 setting shaft snap ring from the input shaft.
NOTICE:
Using a shop rug to prevent the snap ring from being scat-
tered.

C67821

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MANUAL TRANSMISSION/TRANSAXLE – INPUT SHAFT ASSY (C250)

(b) Using SST and a press, remove the transmission clutch

hub No.2 and 3rd gear from the input shaft.
NOTICE:
SST
Do not tighten SST excessively.
SST 09950–00020

CM0064

9. REMOVE SYNCHRONIZER RING NO.2 (FOR THIRD

SYNCHRONIZER RING)
(a) Remove the synchronizer ring No.2 from the 3rd gear.

C68515

10. REMOVE 3RD GEAR NEEDLE ROLLER BEARING

(a) Remove the 3rd gear needle roller bearing from the input
shaft.

C67823

11. REMOVE TRANSMISSION HUB SLEEVE NO.2

(a) Remove the transmission hub sleeve No.2, 3 synchro-
mesh shifting keys No.2 and 3 synchromesh shifting key
springs No.2 from the transmission clutch hub No.2.
NOTICE:
Using a waste to prevent the shifting key and shifting key
spring from being scattered.

C67832

12. INSPECT INPUT SHAFT

(a) Using a dial indicator, check the shaft runout.
Maximum runout: 0.015 mm (0.00059 in.)
If the runout exceeds the maximum, replace the input shaft.

CM0013

C250 M/T REPAIR MANUAL (RM1020E)

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MANUAL TRANSMISSION/TRANSAXLE – INPUT SHAFT ASSY (C250)

(b) Using a micrometer, measure the outer diameter of the in-

put shaft journal surface.
Standard outer diameter:
Part A: 24.885 – 24.900 mm (0.9797 – 0.9803 in.)
Part B: 28.991 – 29.006 mm (1.1413 – 1.1419 in.)
Part C: 30.985 – 31.000 mm (1.2198 – 1.2204 in.)
Part D: 24.985 – 25.000 mm (0.9836 – 0.9842 in.)
Minimum outer diameter:
Part A: 24.885 mm (0.9797 in.)
Part B: 28.991 mm (1.1413 in.)
Part C: 30.985 mm (1.2198 in.)
Part D: 24.985 mm (0.9836 in.)
A B C D
If the outer diameter is less than the minimum, replace the input
shaft.
SST 99999–60009

C80562

13. INSPECT 4TH GEAR

(a) Using a cylinder gauge, measure the inside diameter of
the 4th gear.
Standard clearance:
34.015 – 34.031 mm (1.3391 – 1.3398 in.)
Maximum clearance:
34.031 mm (1.3398 in.)
If the clearance exceeds the maximum, replace the 4th gear.
C67826

14. INSPECT 3RD GEAR

(a) Using a cylinder gauge, measure the inside diameter of
the 3rd gear.
Standard clearance:
36.015 – 36.031 mm (1.4179 – 1.4185 in.)
Maximum clearance:
36.031 mm (1.4185 in.)
If the clearance exceeds the maximum, replace the 3rd gear.
C67827

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MANUAL TRANSMISSION/TRANSAXLE – INPUT SHAFT ASSY (C250)

15. INSPECT SYNCHRONIZER RING NO.2 (FOR FOURTH

SYNCHRONIZER RING)
(a) Coat the 4th gear cone with gear oil. Check the braking
effect of the synchronizer ring No.2. Turn the synchroniz-
er ring No.2 in one direction while pushing it to the 4th
gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring No.2 and
C67828 4th gear cone. Lightly rub the synchronizer ring No.2 and 4th
gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(b) Check again the braking effect of the synchronizer ring
No.2.
(c) Using a feeler gauge, measure the clearance between
the synchronizer ring No.2 back and 4th gear spline end.
Standard clearance:
0.75 – 1.65 mm (0.0295 – 0.0649 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring and apply a small amount of the fine lapping com-
pound on 4th gear cone.
NOTICE:
C67829 Ensure the fine lapping compound is completely washed
off after rubbing.

16. INSPECT SYNCHRONIZER RING NO.2 (FOR THIRD

SYNCHRONIZER RING)
(a) Coat the 3rd gear cone with gear oil. Check the braking
effect of the synchronizer ring No.2. Turn the synchroniz-
er ring No.2 in one direction while pushing it to the 3rd
gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the
fine lapping compound between the synchronizer ring No.2 and
C67830 3rd gear cone. Lightly rub the synchronizer ring No.2 and 3rd
gear cone together.
NOTICE:
Ensure the fine lapping compound is completely washed
off after rubbing.
(b) Check again the braking effect of the synchronizer ring
No.2.

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MANUAL TRANSMISSION/TRANSAXLE – INPUT SHAFT ASSY (C250)

(c) Using a feeler gauge, measure the clearance between

the synchronizer ring No.2 back and 3rd gear spline end.
Standard clearance:
0.75 – 1.65 mm (0.0295 – 0.0649 in.)
If the clearance is less than the minimum, replace the synchro-
nizer ring No.2 and apply a small amount of the fine lapping
compound on the 3rd gear cone.
NOTICE:
C67831 Ensure the fine lapping compound is completely washed
off after rubbing.
17. INSPECT TRANSMISSION HUB SLEEVE NO.2
(a) Check the sliding condition between the transmission hub
sleeve No.2 and transmission clutch hub No.2.
(b) Check that the spline gear’s edges of the transmission
hub sleeve No.2 is not worn down.

C67843

(c) Using a vernier calipers, inspect the transmission hub

sleeve No.2 and gear shift fork No.2 as shown in the il-
lustration.
Standard clearance:
0.15 – 0.35 mm (0.0059 – 0.0137 in.)
If the clearance exceeds the standard clearance, replace the
transmission hub sleeve No.2 and gear shift fork No.2.

C67842

18. INSTALL TRANSMISSION HUB SLEEVE NO.2

(a) Coat the transmission hub sleeve No.2 with gear oil,
install it to the transmission clutch hub No.2.
NOTICE:
Do not set the transmission hub sleeve No.2 and the trans-
mission clutch hub in incorrect orientation.
(b) Install the 2 synchromesh key springs with 3 synchro-
mesh shifting keys No.2 to the transmission clutch hub
C67833 No.2.

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MANUAL TRANSMISSION/TRANSAXLE – INPUT SHAFT ASSY (C250)

19. INSTALL 3RD GEAR NEEDLE ROLLER BEARING

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

C67823

20. INSTALL 3RD GEAR

(a) Coat the 3rd gear with gear oil, install it to the input shaft.

C67834

21. INSTALL SYNCHRONIZER RING NO.2 (FOR THIRD

Key Position SYNCHRONIZER RING)
(a) Coat the synchronizer ring No.2 with gear oil, install it to
the 3rd gear.
HINT:
The synchronizer ring No.2 (for 3rd) is a gray color.

For 3rd gear

C82010

22. INSTALL TRANSMISSION CLUTCH HUB NO.2

(a) Using SST and a press, install the transmission clutch
hub No.2 to the input shaft.
SST 09316–60011 (09316–00021)
NOTICE:
Paying attention to the proper position, fit the synchro-
SST mesh shifting key into the groove of the synchronizer ring.

C80563

(b) Select a snap ring that will allow the minimum axial play.
Standard clearance:
0.1 mm (0.0039 in.) or less.
Mark Thickness mm (in) Mark Thickness mm (in)
0 2.30 (0.0906) 3 2.48 (0.0976)
1 2.36 (0.0929) 4 2.54 (0.1000)
2 2.42 (0.0953) 5 2.60 (0.1024)

C67837

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MANUAL TRANSMISSION/TRANSAXLE – INPUT SHAFT ASSY (C250)

23. INSTALL SYNCHRONIZER RING NO.2 (FOR FOURTH

SYNCHRONIZER RING)
Key Position
(a) Coat the synchronizer ring No.2 with gear oil, install it to
the transmission clutch hub No.2.
HINT:
The synchronizer ring No.2 (for 4th) is a yellow copper color.

For 4th gear

D30573

24. INSTALL 4TH GEAR NEEDLE ROLLER BEARING

(a) Coat the 4th gear needle roller bearing and 4th gear bear-
ing spacer with gear oil, install it to the transmission clutch
hub No.2.

C80560

25. INSTALL 4TH GEAR

(a) Coat the 4th gear with gear oil, install it to the input shaft.

C80564

26. INSTALL INPUT SHAFT REAR RADIAL BALL

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

C80565

(b) Select a snap ring that will allow minimum axial play.
Standard clearance:
0.1 mm (0.0039 in.) or less
Mark Thickness mm (in) Mark Thickness mm (in)
A 2.29 (0.0901) D 2.47 (0.0972)
B 2.35 (0.0925) E 2.53 (0.0996)
C 2.41 (0.0948) F 2.59 (0.1019)

If the clearance is less than the limit, replace the input shaft rear
C80566 radial ball bearing.

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MANUAL TRANSMISSION/TRANSAXLE – INPUT SHAFT ASSY (C250)

27. INSPECT 3RD GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the radial clearance be-
tween the 3rd gear.
Standard clearance:
0.015 – 0.058 mm (0.0006 – 0.0023 in.)
If the clearance is less than the limit, replace the 3rd gear.

C67815

28. INSPECT 4TH GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the radial clearance be-
tween the 4th gear.
Standard clearance:
0.015 – 0.058 mm (0.0006 – 0.0023 in.)
If the clearance is less than the limit, replace the 4th gear.

C80558

29. INSPECT 3RD GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the 3rd thrust clearance.
Standard clearance:
0.1 – 0.35 mm (0.0039 – 0.0138 in.)

C67816

30. INSPECT 4TH GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the 4th thrust clearance.
Standard clearance:
0.1 – 0.55 mm (0.0039 – 0.0217 in.)
If the clearance is less than the limit, replace the 4th gear.

C80557

C250 M/T REPAIR MANUAL (RM1020E)