OUTPUT SHAFT REASSEMBLY


  1. INSTALL OUTPUT SHAFT FRONT BEARING


    1. A0136AEE01

      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

    A0137E1

    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 TRANSMISSION CLUTCH HUB NO.1


    1. A0137BC

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

    2. A0137L0E01

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

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

      Note

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

  6. INSTALL CLUTCH HUB NO.1 SHAFT SNAP RING


    1. A0136R8

      Select a snap ring that allows the minimum axial play.

      Standard clearance
      0 to 0.1 mm (0 to 0.0039 in.)
      Mark

      Thickness mm

      (in.)

      		 Mark

      Thickness mm

      (in.)
      A 2.28 (0.0898) D 2.46 (0.0969)
      B 2.34 (0.0921) E 2.52 (0.0992)
      C 2.40 (0.0945) F 2.58 (0.1016)
    2. A01370L

      Using a snap ring expander, install a 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 (0.0039 to 0.0138 in.)
      Maximum clearance
      0.35 mm (0.0138 in.)

  8. INSPECT 1ST GEAR RADIAL CLEARANCE


    1. A0136PD

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

      Standard clearance
      0.015 to 0.056 mm (0.0006 to 0.0022 in.)
      Maximum clearance
      0.056 mm (0.0022 in.)

      If the clearance exceeds the maximum, replace the 1st gear needle roller bearing or the shaft.

  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 withe 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


    1. A0135TZE01

      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


    1. A01391R

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

      Standard clearance
      0.10 to 0.55 mm (0.0039 to 0.0217 in.)
      Maximum clearance
      0.55 mm (0.0217 in.)

  15. INSPECT 2ND GEAR RADIAL CLEARANCE


    1. A0138M5

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

      Standard clearance
      0.015 to 0.056 mm (0.0006 to 0.0023 in.)
      Maximum clearance
      0.056 mm (0.0006 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


    1. A0137KAE01

      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


    1. A0137ICE01

      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


    1. A0136Z9E01

      Select a snap ring, using the table below, that makes the thrust clearance of the 5th driven gear less than 0.1 mm (0.0039 in.).

      Mark

      Thickness mm

      (in.)

      		 Mark

      Thickness mm

      (in.)
      A 2.22 (0.0874) F 2.52 (0.0992)
      B 2.28 (0.0898) G 2.58 (0.1016)
      C 2.34 (0.0921) H 2.64 (0.1039)
      D 2.40 (0.0945) J 2.70 (0.1063)
      E 2.46 (0.0969) - -
    2. A0137O6

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

  20. INSTALL OUTPUT SHAFT REAR BEARING


    1. A0138SME02

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

      SST
      09950-60010   ( 09951-00370 )