Page 3529 of 5135

ABC
D
C80562
C67826
C67827
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (C250)
41±41
C250 M/T REPAIR MANUAL (RM1020E)
(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.)
If the outer diameter is less than the minimum, replace the input
shaft.
SST 99999±60009
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.
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.
Page 3530 of 5135

C67828
C67829
C67830
41±42
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
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
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:
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
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.
Page 3531 of 5135

C67831
C67843
C67842
C67833
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (C250)
41±43
C250 M/T REPAIR MANUAL (RM1020E)
(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:
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.
(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.
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
No.2.
Page 3532 of 5135

C67823
C67834
C82010
Key Position
For 3rd gear
C80563
SST
C67837
41±44
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
19. INSTALL 3RD GEAR NEEDLE ROLLER BEARING
(a) Coat the 3rd gear needle roller bearing with gear oil,
install it to the input shaft.
20. INSTALL 3RD GEAR
(a) Coat the 3rd gear with gear oil, install it to the input shaft.
21. INSTALL SYNCHRONIZER RING NO.2 (FOR THIRD
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.
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-
mesh shifting key into the groove of the synchronizer ring.
(b) Select a snap ring that will allow the minimum axial play.
Standard clearance:
0.1 mm (0.0039 in.) or less.
MarkThickness mm (in)MarkThickness mm (in)
02.30 (0.0906)32.48 (0.0976)
12.36 (0.0929)42.54 (0.1000)
22.42 (0.0953)52.60 (0.1024)
Page 3533 of 5135

D30573
Key Position
For 4th gear
C80560
C80564
C80565
SST
C80566
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (C250)
41±45
C250 M/T REPAIR MANUAL (RM1020E)
23. INSTALL SYNCHRONIZER RING NO.2 (FOR FOURTH
SYNCHRONIZER RING)
(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.
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.
25. INSTALL 4TH GEAR
(a) Coat the 4th gear with gear oil, install it to the input shaft.
26. INSTALL INPUT SHAFT REAR RADIAL BALL
BEARING
(a) Using SST and a press, install the input shaft rear radial
ball bearing to the input shaft.
(b) Select a snap ring that will allow minimum axial play.
Standard clearance:
0.1 mm (0.0039 in.) or less
MarkThickness mm (in)MarkThickness mm (in)
A2.29 (0.0901)D2.47 (0.0972)
B2.35 (0.0925)E2.53 (0.0996)
C2.41 (0.0948)F2.59 (0.1019)
If the clearance is less than the limit, replace the input shaft rear
radial ball bearing.
Page 3534 of 5135
C67815
C80558
C67816
C80557
41±46
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
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.
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.
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.)
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.
Page 3535 of 5135
410DE±01
D30519
Input Shaft
Syncronizer Ring No.2 (For 3rd)
Syncromesh Shifting Key No.2
Syncromesh Shifting Key Spring No.2
Syncronizer Ring No.2 (For 4th)
3rd Gear Needle Roller Bearing
3rd Gear
Transmission Hub Sleeve No.2
Clutch Hub No.2 Setting Shaft Snap Ring
4th Gear Bearing Spacer
4th Gear Needle Roller Bearing
4th Gear
Input Shaft Rear Redial Ball Bearing
Input Shaft Rear Bearing
Shaft Snap Ring
Transmission Clutch Hub No.2
x3
x3
± MANUAL TRANSMISSION/TRANSAXLEINPUT SHAFT ASSY (C250)
41±37
C250 M/T REPAIR MANUAL (RM1020E)
INPUT SHAFT ASSY (C250)
COMPONENTS
Page 3536 of 5135
410DD±01
D30524
C80550
C67601
C67602
41±4
± MANUAL TRANSMISSION/TRANSAXLEMANUAL TRANSAXLE ASSY (C250)
C250 M/T REPAIR MANUAL (RM1020E)
OVERHAUL
1. REMOVE MANUAL TRANSMISSION FILLER PLUG
(a) Remove the manual transmission filler plug and gasket
from the manual transmission case.
2. REMOVE DRAIN (MTM) PLUG SUB±ASSY
(a) Remove the drain plug and gasket from the manual trans-
mission case.
3. REMOVE SPEEDOMETER DRIVEN HOLE COVER SUB±ASSY
(a) Remove the bolt and speedometer driven hole cover sub±assy.
(b) Remove the O±ring from the speedometer driven hole cover sub±assy.
4. REMOVE CLUTCH RELEASE FORK SUB±ASSY
(a) Remove the clutch release fork sub±assy with clutch re-
lease bearing assy from the front transaxle case.
5. REMOVE CLUTCH RELEASE BEARING ASSY
(a) Remove the clutch release bearing clip and clutch release
bearing assy from the clutch release fork sub±assy.