OUTPUT SHAFT REASSEMBLY


  1. INSTALL TRANSMISSION HUB SLEEVE NO.2


    1. A01KI0O

      Apply gear oil to the sliding part of the transmission hub sleeve No. 2 and install it to the transmission clutch hub No. 2.

      Note

      Be sure of the direction of the transmission hub sleeve No. 2 and that of the transmission clutch hub No. 2.

    2. Install the 2 synchromesh shifting key springs No. 2 and the 3 synchromesh shifting keys No. 2 to the transmission clutch hub No. 2.

      Note

      Do not set both opening of the shifting key springs in the opposite position.

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    1. A01KG0E

      Apply gear oil to the 3rd gear needle roller bearing and install it to the output shaft.

  3. INSTALL 3RD GEAR


    1. A01KH5GE02

      Apply gear oil to the 3rd gear and install it to the output shaft.

  4. INSTALL SYNCHRONIZER RING NO.2 (FOR THIRD SYNCHRONIZER RING)


    1. A01KGN2E02

      Apply gear oil to the synchronizer ring No. 2 and install it to the 3rd gear.

  5. INSTALL TRANSMISSION CLUTCH HUB NO.2


    1. A01KHU5E01

      Using SST, install transmission clutch hub No. 2 to the output shaft.

      SST
      09608-06041

      Note


      • Install with aligning the synchronizer ring key No. 2 groove and the shifting key position.

      • 3rd gear should rotate lightly.

    2. A01KIFL

      Select the clutch hub shaft snap ring so that the gap between the transmission clutch hub No. 2 and the shaft snap ring No. 2 thrust will be within the specification. Using a brass bar and a hammer, install it to the output shaft.

      Standard clearance
      0.1 mm (0.0039 in.) or less
      Mark Thickness mm (in.)
      A 1.80 to 1.85 (0.0709 to 0.0728)
      B 1.85 to 1.90 (0.0728 to 0.0748)
      C 1.90 to 1.95 (0.0748 to 0.0768)
      D 1.95 to 2.00 (0.0768 to 0.0787)
      E 2.00 to 2.05 (0.0787 to 0.0807)
      F 2.05 to 2.10 (0.0807 to 0.0827)
      G 2.10 to 2.15 (0.0827 to 0.0846)

      Note

      Do not damage the sliding surface of the bearing.

  6. INSTALL 2ND GEAR NEEDLE ROLLER BEARING


    1. A01KH8H

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

  7. INSTALL 2ND GEAR


    1. A01KFRNE02

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

  8. INSTALL SYNCHRONIZER RING NO.1 (FOR SECOND SYNCHRONIZER RING)


    1. A01KGP7

      Apply gear oil to the synchronizer ring No. 1 and install it to the 2nd gear.

  9. INSTALL REVERSE GEAR


    1. Apply gear oil to the reverse gear and install it to the transmission clutch hub No. 1.

    2. A01KFZN

      Using a screwdriver, install the 3 synchromesh shifting key springs No. 1 and the 3 synchromesh shifting keys No. 1 to the transmission clutch hub No. 1.

  10. INSTALL TRANSMISSION CLUTCH HUB NO.1


    1. A01KFAIE01

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

      SST
      09316-60011   ( 09316-00041 )

      Note


      • Install with checking the synchronizer ring key No. 1 groove and the synchromesh shifting key No. 1 position.

      • 1st gear should rotate.

    2. A01KGMU

      Select the bearing shaft snap ring so that the thrust gap between the transmission clutch hub No. 1 and the bearing shaft snap ring will be within the specification. Using a brass bar and a hammer, install it to the output shaft.

      Standard clearance
      0.1 mm (0.0039 in.) or less
      Mark Thickness mm (in.)
      A 2.30 to 2.35 (0.0906 to 0.0925)
      B 2.35 to 2.40 (0.0925 to 0.0945)
      C 2.40 to 2.45 (0.0945 to 0.0965)
      D 2.45 to 2.50 (0.0965 to 0.0984)
      E 2.50 to 2.55 (0.0984 to 0.1004)
      F 2.55 to 2.60 (0.1004 to 0.1024)
      G 2.60 to 2.65 (0.1024 to 0.1043)

      Note

      Do not damage the sliding surface of the bearing.

  11. INSTALL 1ST GEAR BEARING SPACER


    1. A01KHA6

      Apply gear oil to the 1st gear bearing spacer, and install it to the output shaft.

  12. INSTALL 1ST GEAR NEEDLE ROLLER BEARING


    1. A01KFOC

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

  13. INSTALL 1ST GEAR THRUST WASHER PIN OR BALL


    1. A01KGXA

      Install the 1st gear thrust washer pin into the output shaft.

  14. INSTALL SYNCHRONIZER RING NO.1 (FOR FIRST SYNCHRONIZER RING)


    1. A01KGTY

      Apply gear oil to the synchronizer ring No. 1 install it to the 1st gear.

  15. INSTALL 1ST GEAR


    1. A01KFGLE02

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

  16. INSTALL 1ST GEAR THRUST WASHER


    1. A01KFQ4E02

      Apply gear oil to the 1st gear thrust washer and install it to the output shaft.

  17. INSTALL OUTPUT SHAFT CENTER BEARING


    1. A01KHB1E01

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

      SST
      09316-60011   ( 09316-00031 )

      Note

      Install so that the snap ring groove of the bearing will face to the rear side.

  18. INSTALL 5TH GEAR


    1. A01KHV8E01

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

      SST
      09316-60011   ( 09316-00031 )

      Note


      • Check that the 5th gear and the spline of the output shaft match before installing.

      • Put the convex part of the gear to the front side.

  19. INSPECT 1ST GEAR THRUST CLEARANCE


    1. A01KG5X

      Using a feeler gauge, check the thrust clearance of the 1st gear.

      Standard clearance
      0.20 to 0.45 mm (0.0079 to 0.0177 in.)

  20. INSPECT 2ND GEAR THRUST CLEARANCE


    1. A01KGGO

      Using a feeler gauge, check the thrust clearance of the 2nd gear.

      Standard clearance
      0.10 to 0.25 mm (0.0039 to 0.0098 in.)

  21. INSPECT 3RD GEAR THRUST CLEARANCE


    1. A01KIKD

      Using a feeler gauge, check the thrust clearance of the 3rd gear.

      Standard clearance
      0.10 to 0.25 mm (0.0039 to 0.0098 in.)

  22. INSPECT 1ST GEAR RADIAL CLEARANCE


    1. A01KH70

      Using a dial indicator, check the radial clearance of the 1st gear.

      Standard clearance
      0.020 to 0.073 mm (0.0008 to 0.0029 in.)

      If the clearance is out of the specification, replace the 1st gear needle roller bearing with a new one.

  23. INSPECT 2ND GEAR RADIAL CLEARANCE


    1. A01KFQT

      Using a dial indicator, check the radial clearance of the 2nd gear.

      Standard clearance
      0.015 to 0.068mm (0.0006 to 0.0027 in.)

      If the clearance is out of the specification, replace the 2nd gear needle roller bearing with a new one.

  24. INSPECT 3RD GEAR RADIAL CLEARANCE


    1. A01KHFA

      Using a dial indicator, check the radial clearance of the 3rd gear.

      Standard clearance
      0.015 to 0.068 mm (0.0006 to 0.0027 in.)

      If the clearance is out of the specification, replace the 3rd gear needle roller bearing with a new one.