OUTPUT SHAFT REASSEMBLY

CAUTION / NOTICE / HINT

Note:

When replacing any tapered roller bearing, replace both the tapered roller bearing and tapered roller bearing outer race with new ones.

PROCEDURE

  1. INSTALL FRONT OUTPUT SHAFT BEARING

    1. G021374N01

      Using SST and a press, install the front output shaft bearing to the output shaft.

      09710-22021

      09710-01051

      Note:

      Do not damage or deform the cage of the front output shaft bearing.

  2. INSTALL 1ST GEAR NEEDLE ROLLER BEARING

    1. C303224

      Coat the 1st gear needle roller bearing with gear oil, and install it to the output shaft.

  3. INSTALL 1ST GEAR

    1. G021376

      Coat the 1st gear with gear oil, and install it to the output shaft.

  4. INSTALL 1ST GEAR SYNCHRONIZER RING

    1. G021377

      Coat the 1st gear synchronizer ring with gear oil, and install it to the 1st gear.

  5. INSTALL NO. 1 TRANSMISSION CLUTCH HUB

    1. C232585C01

      *1

      No. 1 Shifting Key Spring

      *2

      Reverse Gear

      *3

      No. 1 Shifting Key

      *4

      No. 1 Transmission Clutch Hub

      Install the reverse gear to the No. 1 transmission clutch hub, and then install the 3 No. 1 shifting keys and 2 No. 1 shifting key springs.

      Note:

      Assemble the reverse gear and No. 1 transmission clutch hub in the correct order as shown in the illustration.

    2. G021379N01

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

      09316-60011

      09316-00011

      09316-00071

      Note:

      Install the No. 1 transmission clutch hub in the correct direction as shown in the illustration.

  6. INSTALL NO. 1 CLUTCH HUB SHAFT SNAP RING

    1. G021380C03

      *a

      Mark

      Select a new No. 1 clutch hub shaft snap ring that allows for minimum axial play.

      Standard Clearance

      0 to 0.1 mm (0 to 0.00393 in.)

      No. 1 Clutch Hub Shaft Snap Ring Thickness

      Part No.

      Mark

      Thickness

      mm (in.)

      90520-32014

      A

      2.28 (0.0898)

      90520-32015

      B

      2.34 (0.0921)

      90520-32016

      C

      2.40 (0.0945)

      90520-32017

      D

      2.46 (0.0969)

      90520-32018

      E

      2.52 (0.0992)

      90520-32019

      F

      2.58 (0.1016)
    2. C118340

      Using a brass bar and a hammer, install the No. 1 clutch hub shaft snap ring to the output shaft.

      Tip:

      Use a piece of cloth to keep the No. 1 clutch hub shaft snap ring from flying off.

  7. INSTALL 2ND GEAR BEARING SPACER

    1. G021383

      Coat the 2nd gear bearing spacer with gear oil, and install it to the output shaft.

  8. INSTALL 2ND GEAR NEEDLE ROLLER BEARING

    1. G021384

      Coat the 2nd gear needle roller bearing with gear oil, and install it to the output shaft.

  9. INSTALL 2ND GEAR SYNCHRONIZER RING

    1. G021385

      Coat the 2nd gear synchronizer ring with gear oil, and install it to the reverse gear.

  10. INSTALL 2ND GEAR

    1. G021386

      Coat the 2nd gear with gear oil, and install it to the output shaft.

  11. INSTALL 3RD DRIVEN GEAR

    1. C232575N01

      Using SST and a press, install the 3rd driven gear to the output shaft.

      09316-60011

      09316-00041

      Note:

      Install the 3rd driven gear while aligning the cutout of the 2nd gear synchronizer ring and No. 1 shifting key.

  12. INSTALL OUTPUT SHAFT SPACER

    1. G021357

      Install the output shaft spacer to the output shaft.

  13. INSTALL 4TH DRIVEN GEAR

    1. G021390N01

      Using SST and a press, install the 4th driven gear to the output shaft.

      09223-00010

      09316-60011

      09316-00021

  14. INSTALL 5TH DRIVEN GEAR

    1. G021396N01

      Using SST and a press, install the 5th driven gear to the output shaft.

      09223-00010

      09316-60011

      09316-00021

  15. INSTALL COUNTER 5TH GEAR SHAFT SNAP RING

    1. G021397C03

      *a

      Mark

      Using the table below, select a new counter 5th gear shaft snap ring that makes the thrust clearance of the 5th driven gear less than 0.1 mm (0.00393 in.).

      Counter 5th Gear Shaft Snap Ring Thickness

      Part No.

      Mark

      Thickness

      mm (in.)

      90520-27070

      A

      2.22 (0.0874)

      90520-27071

      B

      2.28 (0.0898)

      90520-27072

      C

      2.34 (0.0921)

      90520-27073

      D

      2.40 (0.0945)

      90520-27074

      E

      2.46 (0.0969)

      90520-27075

      F

      2.52 (0.0992)

      90520-27076

      G

      2.58 (0.1016)

      90520-27077

      H

      2.64 (0.1039)

      90520-27078

      J

      2.70 (0.1063)
    2. G021401

      Using a brass bar and a hammer, install the counter 5th gear shaft snap ring to the output shaft.

      Tip:

      Use a piece of cloth to keep the counter 5th gear shaft snap ring from flying off.

  16. INSPECT 1ST GEAR THRUST CLEARANCE

    Click here

  17. INSPECT 2ND GEAR THRUST CLEARANCE

    Click here

  18. INSPECT 1ST GEAR RADIAL CLEARANCE

    Click here

  19. INSPECT 2ND GEAR RADIAL CLEARANCE

    Click here

  20. INSTALL REAR OUTPUT SHAFT BEARING

    1. C121092N01

      Using SST and a press, install the rear output shaft bearing to the output shaft.

      09612-22011

      Note:

      Do not damage or deform the cage of the rear output shaft bearing.