OUTPUT SHAFT REASSEMBLY

PROCEDURE


  1. INSTALL FRONT OUTPUT SHAFT BEARING


    1. A01VEP0E01

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

      SST
      09710-22021   ( 09710-01051 )

  2. INSTALL 1ST GEAR NEEDLE ROLLER BEARING


    1. A01VGIL

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

  3. INSTALL 1ST GEAR


    1. A01VHBH

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

  4. INSTALL 1ST GEAR SYNCHRONIZER RING


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

  5. INSTALL NO. 1 TRANSMISSION CLUTCH HUB


    1. A01VFYY

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

    2. A01VEQTE01

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

      SST
      09316-60011   ( 09316-00011, 09316-00071 )

      Note

      Install the No. 1 transmission clutch hub set in the correct orientation shown in the illustration.

  6. INSTALL NO. 1 CLUTCH HUB SHAFT SNAP RING


    1. A01VDLRE04
      Text in Illustration
      *a Alignment Mark

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

      Standard clearance
      0 to 0.1 mm (0 to 0.0039 in.)
      Snap Ring Thickness
      Part No. Mark

      Thickness

      mm (in.)
      90520-32014 A 2.280 (0.0898)
      90520-32015 B 2.340 (0.0921)
      90520-32016 C 2.400 (0.0945)
      90520-32017 D 2.460 (0.0969)
      90520-32018 E 2.520 (0.0992)
      90520-32019 F 2.580 (0.1016)
    2. A01VKEM

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

    3. Inspect the 1st gear thrust clearance and radial clearance Click here.

      If either clearance is more than the maximum, check the installation condition of the No. 1 transmission clutch hub and repeat the procedure to select a No. 1 clutch hub shaft snap ring.

  7. INSTALL 2ND GEAR BEARING SPACER


    1. A01VG20

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

  8. INSTALL 2ND GEAR NEEDLE ROLLER BEARING


    1. A01VFW7

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

  9. INSTALL 2ND SYNCHRONIZER RING


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

  10. INSTALL 2ND GEAR


    1. A01VH3D

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

  11. INSTALL 3RD DRIVEN GEAR


    1. A01VHY5E01

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

      SST
      09316-60011   ( 09316-00041 )

      Note

      Install the 3rd driven gear while making sure that the cutout of the 2nd gear synchronizer ring and the No. 1 clutch hub shifting key are aligned.

    2. Inspect the 2nd gear thrust clearance and radial clearance Click here.

      If the clearance is more than the maximum, check the installation condition of the 3rd gear.

  12. INSTALL OUTPUT SHAFT SPACER


    1. A01VH4C

      Install the output shaft spacer to the output shaft.

  13. INSTALL 4TH DRIVEN GEAR


    1. A01VG9OE01

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

      SST
      09223-00010
      09316-60011   ( 09316-00021 )

  14. INSTALL 5TH DRIVEN GEAR


    1. A01VFLYE01

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

      SST
      09223-00010
      09316-60011   ( 09316-00021 )

  15. INSTALL COUNTER 5TH GEAR SHAFT SNAP RING


    1. A01VM5KE05
      Text in Illustration
      *a Alignment Mark

      Using the table below, select a new counter 5th gear shaft snap ring that makes the thrust clearance of the counter 5th driven gear less than 0.1 mm (0.00394 in.).

      Snap Ring Thickness
      Part No. Mark

      Thickness

      mm (in.)
      90520-27070 A 2.220 (0.0874)
      90520-27071 B 2.280 (0.0898)
      90520-27072 C 2.340 (0.0921)
      90520-27073 D 2.400 (0.0945)
      90520-27074 E 2.460 (0.0969)
      90520-27075 F 2.520 (0.0992)
      90520-27076 G 2.580 (0.1016)
      90520-27077 H 2.640 (0.1039)
      90520-27078 J 2.700 (0.1063)
    2. A01VHK3

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

  16. INSTALL REAR OUTPUT SHAFT BEARING


    1. A01VJ6CE01

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

      SST
      09612-22011