OUTPUT SHAFT REASSEMBLY


  1. INSTALL NO. 2 TRANSMISSION HUB SLEEVE


    1. A01KGWT

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

      Note

      Make sure that the No. 2 transmission hub sleeve and No. 2 transmission clutch hub are oriented in the correct direction.

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

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    1. A01KG0E

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

  3. INSTALL 3RD GEAR


    1. A01KH5GE02

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

  4. INSTALL NO. 2 SYNCHRONIZER RING (for 3rd Gear)


    1. A01KGN2E02

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

  5. INSTALL NO. 2 TRANSMISSION CLUTCH HUB


    1. A01KHU5E01

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

      SST
      09608-06041

      Note


      • Install it with the No. 2 synchronizer ring grooves aligned with the shifting key positions.

      • Make sure that the 3rd gear rotates smoothly.

    2. A01KIFL

      Select a clutch hub set shaft snap ring so that the clearance between the No. 2 transmission clutch hub and shaft snap ring is within the specified values. Then install it onto the output shaft.

      Standard clearance
      0.1 mm (0.0039 in.) or less

      Note

      Do not damage the sliding surface of the bearing.

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

  6. INSTALL 2ND GEAR NEEDLE ROLLER BEARING


    1. A01KH8H

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

  7. INSTALL 2ND GEAR


    1. A01KFRNE02

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

  8. INSTALL NO. 1 SYNCHRONIZER RING (for 2nd Gear)


    1. A01KEB3

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

  9. INSTALL REVERSE GEAR


    1. A01KFZN

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

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

  10. INSTALL NO. 1 TRANSMISSION CLUTCH HUB


    1. A01KFAIE01

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

      SST
      09316-60011   ( 09316-00041 )

      Note


      • Make sure that the No. 1 synchronizer ring grooves and synchromesh shifting keys are in place.

      • Make sure that the 1st gear rotates smoothly.

    2. A01KGMU

      Select a bearing shaft snap ring so that the clearance between the No. 1 transmission clutch hub and bearing shaft snap ring is within the specified values. Then install it onto the output shaft.

      Standard clearance
      0.1 mm (0.0039 in.) or less

      Note

      Do not damage the sliding surface of the bearing.

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

  11. INSTALL 1ST GEAR BEARING SPACER


    1. A01KHA6

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

  13. INSTALL 1ST GEAR THRUST WASHER PIN


    1. A01KGXA

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

  14. INSTALL NO. 1 SYNCHRONIZER RING (for 1st Gear)


    1. A01KGXH

      Apply gear oil to the No. 1 synchronizer ring, and install it onto the output shaft.

  15. INSTALL 1ST GEAR


    1. A01KFGLE02

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

  16. INSTALL 1ST GEAR THRUST WASHER


    1. A01KFQ4E02

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

  17. INSTALL OUTPUT SHAFT CENTER BEARING


    1. A01KHB1E03

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

      SST
      09316-60011   ( 09316-00031 )

      Note

      Install it with the snap ring groove of the bearing facing to the rear side.

  18. INSTALL 5TH GEAR


    1. A01KHV8E03

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

      SST
      09316-60011   ( 09316-00031 )

      Note


      • Check that the 5th gear is fitted into the spline of the output shaft before installing.

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

  19. INSPECT 1ST GEAR THRUST CLEARANCE


    1. A01KHW6E10

      Using a dial indicator, measure 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. A01KHW6E11

      Using a dial indicator, measure 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. A01KIKDE02

      Using a feeler gauge, measure 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, measure 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 not within the specified values, replace the 1st gear needle roller bearing with a new one.

  23. INSPECT 2ND GEAR RADIAL CLEARANCE


    1. A01KFQT

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

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

      If the clearance is not within the specified values, replace the 2nd gear needle roller bearing with a new one.

  24. INSPECT 3RD GEAR RADIAL CLEARANCE


    1. A01KHFA

      Using a dial indicator, measure 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 not within the specified values, replace the 3rd gear needle roller bearing with a new one.