OUTPUT SHAFT REASSEMBLY


  1. INSTALL OUTPUT SHAFT FRONT BEARING


    1. A0136AEE03

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

      SST
      09710-22021   ( 09710-01051 )

  2. INSTALL 1ST GEAR NEEDLE ROLLER BEARING


    1. A01385C

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

  3. INSTALL 1ST GEAR


    1. A0137MJE01

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

  4. INSTALL 1ST GEAR SYNCHRONIZER RING


    1. A0137ULE01

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

  5. INSTALL NO. 1 TRANSMISSION CLUTCH HUB


    1. A0138ES

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

    2. A0137L0E02

      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. A0136R8E01
      Text in Illustration
      *a Mark

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

      Standard clearance
      0 to 0.1 mm (0 to 0.00393 in.)
      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. A0137IL

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

  7. INSPECT 1ST GEAR THRUST CLEARANCE


    1. A0137ZKE01

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

      Standard clearance
      0.10 to 0.35 mm (0.00394 to 0.0137 in.)
      Maximum clearance
      0.35 mm (0.0137 in.)

      If the clearance is more than the maximum, replace the No. 1 transmission clutch hub, 1st gear or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  8. INSPECT 1ST GEAR RADIAL CLEARANCE


    1. A0138AJE01

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

      Standard clearance
      0.015 to 0.056 mm (0.000591 to 0.00220 in.)
      Maximum clearance
      0.056 mm (0.00220 in.)

      If the clearance is more than the maximum, replace the 1st gear needle roller bearing, 1st gear or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  9. INSTALL 2ND GEAR BEARING SPACER


    1. A0136R0E01

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

  10. INSTALL 2ND GEAR NEEDLE ROLLER BEARING


    1. A0136T6E01

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

  11. INSTALL 2ND GEAR SYNCHRONIZER RING


    1. A0137ESE01

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

  12. INSTALL 2ND GEAR


    1. A01368NE01

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

  13. INSTALL 3RD DRIVEN GEAR


    1. A0138MZE01

      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 shifting key are aligned.

  14. INSPECT 2ND GEAR THRUST CLEARANCE


    1. A0138I1E01

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

      Standard clearance
      0.10 to 0.55 mm (0.00394 to 0.0216 in.)
      Maximum clearance
      0.55 mm (0.0216 in.)

      If the clearance is more than the maximum, replace the 2nd gear, No. 1 transmission clutch hub, 3rd driven gear or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  15. INSPECT 2ND GEAR RADIAL CLEARANCE


    1. A0138TQE01

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

      Standard clearance
      0.015 to 0.056 mm (0.000591 to 0.00220 in.)
      Maximum clearance
      0.056 mm (0.00220 in.)

      If the clearance is more than the maximum, replace the 2nd gear needle roller bearing, 2nd gear or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  16. INSTALL OUTPUT SHAFT SPACER


    1. A01369AE01

      Install the output shaft spacer to the output shaft.

  17. INSTALL 4TH DRIVEN GEAR


    1. A0137KAE03

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

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

  18. INSTALL 5TH DRIVEN GEAR


    1. A0137ICE03

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

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

  19. INSTALL COUNTER 5TH GEAR SHAFT SNAP RING


    1. A0136Z9E03
      Text in Illustration
      *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.).

      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. A0137O6E01

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

  20. INSTALL OUTPUT SHAFT REAR BEARING


    1. A0136BNE01

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

      SST
      09950-60010   ( 09951-00370 )