OUTPUT SHAFT REASSEMBLY


  1. INSTALL OUTPUT SHAFT FRONT BEARING

    A0136AEE01

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

      SST
      09710-22021   ( 09710-01051 )

  2. INSTALL 1ST GEAR NEEDLE ROLLER BEARING

    A01385C

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

  3. INSTALL 1ST GEAR

    A0137MJ

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

  4. INSTALL 1ST GEAR SYNCHRONIZER RING

    A0137UL

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

  5. INSTALL NO. 1 TRANSMISSION CLUTCH HUB

    A0138ES

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

    2. A0137L0E01

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

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

      Note

      Install the reverse gear assembly in the correct orientation, as shown in the illustration.

  6. INSTALL NO. 1 CLUTCH HUB SHAFT SNAP RING


    1. A0136R8E01
      Text in Illustration
      *a Mark

      Select a snap ring that allows the minimum axial play.

      Standard clearance
      0 to 0.1 mm (0 to 0.00393 in.)
      Snap Ring Thickness
      Parts 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. A01370L

      Using a snap ring expander, install the new snap ring onto the output shaft.

  7. INSPECT 1ST GEAR THRUST CLEARANCE

    A01370R

    1. 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.)

  8. INSPECT 1ST GEAR RADIAL CLEARANCE

    A0136PD

    1. 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 exceeds the maximum, replace the 1st gear needle roller bearing.

  9. INSTALL 2ND GEAR BEARING SPACER

    A0136R0

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

  10. INSTALL 2ND GEAR NEEDLE ROLLER BEARING

    A0136T6

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

  11. INSTALL 2ND GEAR SYNCHRONIZER RING

    A0137ES

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

  12. INSTALL 2ND GEAR

    A01368N

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

  13. INSTALL 3RD DRIVEN GEAR

    A0135TZE01

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

      SST
      09316-60011   ( 09316-00041 )

  14. INSPECT 2ND GEAR THRUST CLEARANCE

    A01391R

    1. 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.)

  15. INSPECT 2ND GEAR RADIAL CLEARANCE

    A0138M5

    1. Using a dial indicator, measure the 2nd gear radial clearance between the gear and shaft.

      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 exceeds the maximum, replace the 2nd gear needle roller bearing.

  16. INSTALL OUTPUT SHAFT SPACER

    A01369A

    1. Install the output shaft spacer onto the output shaft.

  17. INSTALL 4TH DRIVEN GEAR

    A0137KAE01

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

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

  18. INSTALL 5TH DRIVEN GEAR

    A0137ICE01

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

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

  19. INSTALL COUNTER 5TH GEAR SHAFT SNAP RING

    A0136Z9E03

    1. Select a snap ring, using the table below, that makes the thrust clearance of the 5th driven gear less than 0.1 mm (0.00393 in.).

      Text in Illustration
      *a Mark
      Snap Ring Thickness
      Parts 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. A0137O6

      Using a brass bar and hammer, tap the new snap ring onto the output shaft.

  20. INSTALL OUTPUT SHAFT REAR BEARING

    A0138SME02

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

      SST
      09950-60010   ( 09951-00370 )