OUTPUT SHAFT REASSEMBLY

PROCEDURE

  1. INSTALL NEEDLE ROLLER BEARING

    1. C112406

      Coat the needle roller bearing with gear oil, and install it into the No. 2 output shaft.

  2. INSTALL REVERSE DRIVEN GEAR

    1. C363608

      Coat the reverse driven gear with gear oil, and install it into the No. 2 output shaft.

  3. INSTALL NO. 4 TRANSMISSION CLUTCH HUB

    1. C116552E05

      Install the key spring and 2 shifting keys to the clutch hub.

      Table 1. Text in Illustration

      *1

      Hub Sleeve

      *2

      Reverse Driven Gear Synchronizer Ring

      *3

      Shifting Key

      *4

      Key Spring

      *5

      Clutch Hub

      *6

      Claw
      Tip:

      • Install the shifting key with the grooves on the clutch hub side.

      • Install the key spring with the claw on the clutch hub side.

      • Refer to the illustration when installing the key spring and shifting keys.

    2. Install the hub sleeve to the reverse driven gear as shown in the illustration.

    3. C116199E01

      Coat the No. 4 transmission clutch hub with gear oil, and install it into the No. 2 output shaft.

    4. Using SST and a press, press in the reverse gear and No. 4 transmission clutch hub into the No. 2 output shaft.

      09308-14010

      Note:

      After installation, make sure that the gear and synchronizer ring move smoothly.

      Tip:

      Make sure that the protruding part on the synchronizer ring is fitted into the groove of the clutch hub.

  4. INSTALL SHAFT SNAP RING

    1. C363609E01

      Select a new snap ring, using the table below, that makes the thrust clearance of the No. 4 transmission clutch hub less than 0.1 mm (0.00394 in.).

      Standard shaft snap ring thickness

      Mark

      Specified Condition

      Mark

      Specified Condition

      A

      2.25 to 2.30 mm (0.0886 to 0.0906 in.)

      E

      2.45 to 2.50 mm (0.0965 to 0.0984 in.)

      B

      2.30 to 2.35 mm (0.0906 to 0.0925 in.)

      F

      2.50 to 2.55 mm (0.0984 to 0.100 in.)

      C

      2.35 to 2.40 mm (0.0925 to 0.0945 in.)

      G

      2.55 to 2.60 mm (0.100 to 0.102 in.)

      D

      2.40 to 2.45 mm (0.0945 to 0.0965 in.)

      H

      2.60 to 2.65 mm (0.102 to 0.104 in.)
      Table 2. Text in Illustration

      *1

      Mark
    2. C112456

      Using a brass bar and hammer, tap the snap ring onto the No. 2 output shaft.

  5. INSPECT REVERSE DRIVEN GEAR THRUST CLEARANCE

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  6. INSPECT REVERSE DRIVEN GEAR RADIAL CLEARANCE

    Click here

  7. INSTALL 5TH DRIVEN GEAR

    1. C112402

      Install the output shaft spacer into the No. 2 output shaft.

    2. C112401

      Coat the 2 pieces of the needle roller bearing with gear oil, and install them into the No. 2 output shaft.

    3. C112400

      Install the output shaft spacer into the No. 2 output shaft.

    4. C116206

      Coat the 5th driven gear with gear oil, and install it into the No. 2 output shaft.

  8. INSTALL NO. 3 TRANSMISSION CLUTCH HUB

    1. C116553

      Apply of gear oil to the sleeve and hub.

    2. Install the hub sleeve to the clutch hub.

    3. Install the 3 shifting keys to the clutch hub.

    4. Install the 3 shifting key springs to the clutch hub.

    5. Place the 3 balls in the holes of the shifting keys, and install the hub sleeve while pushing in the balls.

      Note:

      Take care to prevent the balls from scattering.

    6. C116200E01

      Coat the 5th driven gear synchronizer ring with gear oil, and install it to the 5th driven gear.

    7. Using SST and a press, press in the No. 3 transmission clutch hub to the No. 2 output shaft.

      09308-14010

      Tip:

      Make sure that the protruding part on the synchronizer ring is fitted into the groove of the clutch hub.

      Note:

      After installation, make sure that the gear and synchronizer ring move smoothly.

  9. INSTALL SHAFT SNAP RING

    1. C363610E01

      Select a new snap ring, using the table below, that makes the thrust clearance of the No. 3 transmission clutch hub less than 0.1 mm (0.00394 in.).

      Standard shaft snap ring thickness

      Mark

      Specified Condition

      Mark

      Specified Condition

      1

      2.25 to 2.30 mm (0.0886 to 0.0906 in.)

      4

      2.40 to 2.45 mm (0.0945 to 0.0965 in.)

      2

      2.30 to 2.35 mm (0.0906 to 0.0925 in.)

      5

      2.45 to 2.50 mm (0.0965 to 0.0984 in.)

      3

      2.35 to 2.40 mm (0.0925 to 0.0945 in.)

      6

      2.50 to 2.55 mm (0.0984 to 0.100 in.)
      Table 3. Text in Illustration

      *1

      Mark
    2. C112462

      Using a brass bar and hammer, tap the snap ring onto the No. 2 output shaft.

  10. INSPECT 5TH DRIVEN GEAR THRUST CLEARANCE

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  11. INSPECT 5TH DRIVEN GEAR RADIAL CLEARANCE

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  12. INSTALL 6TH DRIVEN GEAR

    1. C116203

      Install the spacer into the No. 2 output shaft.

    2. C116204

      Coat the 2 pieces of the needle roller bearing with gear oil, and install them into the No. 2 output shaft.

    3. C116202

      Coat the 6th gear synchronizer ring with gear oil, and install it into the transmission clutch hub.

    4. C116555

      Coat the 6th driven gear with gear oil, and install it into the No. 2 output shaft.

  13. INSTALL NO. 2 OUTPUT SHAFT REAR BEARING

    1. C112458E02

      Using SST and a press, press in the No. 2 output shaft rear bearing to the No. 2 output shaft.

      09710-04071

      Note:

      After installation, make sure that the gear and synchronizer ring move smoothly.

  14. INSTALL NO. 2 OUTPUT SHAFT BEARING SNAP RING

    1. C363612E01

      Select a new snap ring, using the table below, that makes the thrust clearance of the 6th gear less than 0.1 mm (0.00394 in.).

      Standard No. 2 output shaft bearing snap ring thickness

      Mark

      Specified Condition

      Mark

      Specified Condition

      B

      1.85 to 1.90 mm (0.0728 to 0.0748 in.)

      0

      2.05 to 2.10 mm (0.0807 to 0.0827 in.)

      C

      1.90 to 1.95 mm (0.0748 to 0.0768 in.)

      1

      2.10 to 2.15 mm (0.0827 to 0.0846 in.)

      D

      1.95 to 2.00 mm (0.0768 to 0.0787 in.)

      2

      2.15 to 2.20 mm (0.0846 to 0.0866 in.)

      E

      2.00 to 2.05 mm (0.0787 to 0.0807 in.)

      -

      -
      Table 4. Text in Illustration

      *1

      Mark
    2. C112395

      Using a snap ring expander, install the snap ring onto the No. 2 output shaft.

  15. INSPECT 6TH DRIVEN GEAR THRUST CLEARANCE

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  16. INSPECT 6TH DRIVEN GEAR RADIAL CLEARANCE

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  17. INSTALL NO. 2 OUTPUT SHAFT FRONT BEARING

    1. C112459E01

      Using SST and a press, press in the No. 2 output shaft front bearing into the No. 2 output shaft.

      09309-37010

      09506-30012

  18. INSTALL OUTPUT SHAFT FRONT BEARING

    1. C112466E01

      Using SST and a press, press in the output shaft front bearing into the No. 1 output shaft.

      09309-14040

  19. INSTALL OUTPUT SHAFT FRONT BEARING SHAFT SNAP RING

    1. C112426

      Using a snap ring expander, install a new snap ring into the No. 1 output shaft.

  20. INSTALL 1ST DRIVEN GEAR

    1. C112425

      Coat the needle roller bearing with gear oil, and install it into the No. 1 output shaft.

    2. C363613

      Coat the 1st driven gear with gear oil, and install it into the No. 1 output shaft.

  21. INSTALL NO. 1 TRANSMISSION CLUTCH HUB

    1. C116550

      Apply of gear oil to the sleeve and hub.

    2. Install the hub sleeve to the clutch hub.

    3. Install the 3 shifting keys to the clutch hub.

    4. Install the 3 shifting key springs to the clutch hub.

    5. Place the 3 balls in the holes of the shifting keys, and install the hub sleeve while pushing in the balls.

      Note:

      Take care to prevent the balls from scattering.

    6. C112467E03

      Coat the 3 pieces of the 1st driven gear synchronizer ring set with gear oil, and install them to the 1st driven gear.

    7. Using SST and a press, press in the No. 1 transmission hub sleeve to the No. 1 output shaft.

      09726-40010

      Note:

      After installation, make sure that the gear and synchronizer ring move smoothly.

      Tip:

      Make sure that the protruding part on the synchronizer ring is fitted into the groove of the clutch hub.

  22. INSTALL 2ND DRIVEN GEAR SYNCHRONIZER RING SET

    1. C112422

      Coat the 3 pieces of the 2nd driven gear synchronizer ring set with gear oil, and install them to the No. 1 output shaft.

  23. INSTALL SYNCHROMESH SHIFTING KEY BALL

    1. C116562E01

      Install the key ball onto the No. 1 output shaft.

      Table 5. Text in Illustration

      *1

      Magnet Hand

  24. INSTALL NEEDLE ROLLER BEARING

    1. C112421

      Coat the needle roller bearing with gear oil, and install it into the No. 1 output shaft.

  25. INSTALL 2ND DRIVEN GEAR

    1. C112420

      Coat the 2nd driven gear with gear oil, and install it into the No. 1 output shaft.

  26. INSTALL INNER 2ND DRIVEN GEAR BEARING RACE

    1. C112419

      Align the groove of the inner 2nd driven gear bearing race with the ball, and install it.

  27. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING

    1. C363614E01

      Select a new snap ring, using the table below, that makes the thrust clearance of the 2nd gear less than 0.1 mm (0.00394 in.).

      Standard output shaft bearing shaft snap ring thickness

      Mark

      Specified Condition

      Mark

      Specified Condition

      A

      2.25 to 2.30 mm (0.0886 to 0.0906 in.)

      E

      2.45 to 2.50 mm (0.0965 to 0.0984 in.)

      B

      2.30 to 2.35 mm (0.0906 to 0.0925 in.)

      F

      2.50 to 2.55 mm (0.0984 to 0.100 in.)

      C

      2.35 to 2.40 mm (0.0925 to 0.0945 in.)

      G

      2.55 to 2.60 mm (0.100 to 0.102 in.)

      D

      2.40 to 2.45 mm (0.0945 to 0.0965 in.)

      H

      2.60 to 2.65 mm (0.102 to 0.104 in.)
      Table 6. Text in Illustration

      *1

      Mark
    2. C112418

      Using a snap ring expander, install the snap ring into the No. 1 output shaft.

      Note:

      Do not damage the journal surface of the No. 1 output shaft.

  28. INSPECT 1ST DRIVEN GEAR THRUST CLEARANCE

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  29. INSPECT 1ST DRIVEN GEAR RADIAL CLEARANCE

    Click here

  30. INSPECT 2ND DRIVEN GEAR THRUST CLEARANCE

    Click here

  31. INSPECT 2ND DRIVEN GEAR RADIAL CLEARANCE

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  32. INSTALL 4TH DRIVEN GEAR

    1. C112417

      Install the spacer into the No. 1 output shaft.

    2. C112416

      Coat the 2 pieces of the 4th driven gear needle roller bearing with gear oil, and install them into the No. 1 output shaft.

    3. C116209

      Coat the 4th driven gear with gear oil, and install it into the No. 1 output shaft.

  33. INSTALL NO. 2 TRANSMISSION CLUTCH HUB

    1. C116551

      Apply of gear oil to the sleeve and hub.

    2. Install the hub sleeve to the clutch hub.

    3. Install the 3 shifting keys to the clutch hub.

    4. Install the 3 shifting key springs to the clutch hub.

    5. Place the 3 balls in the holes of the shifting keys, and install the hub sleeve while pushing in the balls.

      Note:

      Take care to prevent the balls from scattering.

    6. Coat the 3 pieces of the 4th driven gear synchronizer ring set with gear oil, and install them into the 4th driven gear.

    7. C112468E01

      Using SST and a press, press in the No. 2 transmission hub sleeve to the No. 1 output shaft.

      09309-14010

      Tip:

      Make sure that the protruding part on the synchronizer ring is fitted into the groove of the clutch hub.

      Note:

      After installation, make sure that the gear and synchronizer ring move smoothly.

  34. INSTALL SHAFT SNAP RING

    1. C363615E01

      Select a new snap ring, using the table below, that makes the thrust clearance of the No. 2 transmission clutch hub less than 0.1 mm (0.00394 in.).

      Standard shaft snap ring thickness

      Mark

      Specified Condition

      Mark

      Specified Condition

      1

      2.25 to 2.30 mm (0.0886 to 0.0906 in.)

      4

      2.40 to 2.45 mm (0.0945 to 0.0965 in.)

      2

      2.30 to 2.35 mm (0.0906 to 0.0925 in.)

      5

      2.45 to 2.50 mm (0.0965 to 0.0984 in.)

      3

      2.35 to 2.40 mm (0.0925 to 0.0945 in.)

      6

      2.50 to 2.55 mm (0.0984 to 0.100 in.)
      Table 7. Text in Illustration

      *1

      Mark
    2. C112469

      Using a brass bar and hammer, tap the snap ring into the No. 1 output shaft.

  35. INSPECT 4TH DRIVEN GEAR THRUST CLEARANCE

    Click here

  36. INSPECT 4TH DRIVEN GEAR RADIAL CLEARANCE

    Click here

  37. INSTALL 3RD DRIVEN GEAR

    1. C112413

      Coat the 3rd driven gear synchronizer ring set with gear oil, and install it into the No. 1 output shaft.

    2. C112412

      Coat the needle roller bearing with gear oil, and install it into the No. 1 output shaft.

    3. C112411

      Install the spacer into the No. 1 output shaft.

    4. C112410

      Coat the 3rd driven gear with gear oil, and install it into the No. 1 output shaft.

  38. INSTALL OUTPUT SHAFT FRONT BEARING

    1. C112465E02

      Using SST and a press, press in the output shaft front bearing into the No. 1 output shaft.

      09308-14010

      Tip:

      When pressing in the bearing, apply force to only the inner race. Do not apply force to the seal.

      Note:

      After installation, make sure that the gear and synchronizer ring move smoothly.

  39. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING

    1. C363616E01

      Select a new snap ring, using the table below, that makes the thrust clearance of the output shaft bearing less than 0.1 mm (0.00394 in.).

      Standard output shaft bearing snap ring thickness

      Mark

      Specified Condition

      Mark

      Specified Condition

      B

      1.85 to 1.90 mm (0.0728 to 0.0748 in.)

      0

      2.05 to 2.10 mm (0.0807 to 0.0827 in.)

      C

      1.90 to 1.95 mm (0.0748 to 0.0768 in.)

      1

      2.10 to 2.15 mm (0.0827 to 0.0846 in.)

      D

      1.95 to 2.00 mm (0.0768 to 0.0787 in.)

      2

      2.15 to 2.20 mm (0.0846 to 0.0866 in.)

      E

      2.00 to 2.05 mm (0.0787 to 0.0807 in.)

      -

      -
      Table 8. Text in Illustration

      *1

      Mark
    2. C112408

      Using a snap ring expander, install the snap ring onto the No. 1 output shaft.

  40. INSPECT 3RD DRIVEN GEAR THRUST CLEARANCE

    Click here

  41. INSPECT 3RD DRIVEN GEAR RADIAL CLEARANCE

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