OUTPUT SHAFT REASSEMBLY


  1. INSTALL NO. 2 TRANSMISSION HUB SLEEVE


    1. A01DPX5E02

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

      Note

      Make sure that the No. 2 hub sleeve and No. 2 clutch hub are installed facing the proper directions.

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

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    1. A01DQSXE01

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

  3. INSTALL 3RD GEAR


    1. A01DUAAE01

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

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


    1. A01DO2AE01

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

  5. INSTALL NO. 2 TRANSMISSION CLUTCH HUB


    1. A01DTMVE01

      Using SST and a press, install the No. 2 clutch hub to the output shaft.

      SST
      09608-06041

      Note


      • Install the hub while aligning the positions of the shifting keys with the key grooves of the No. 2 synchronizer ring.

      • Make sure the 3rd gear rotates smoothly.

    2. Select a snap ring that makes the clearance between the No. 2 clutch hub and snap ring within the specification.

      Standard clearance
      0.10 mm (0.00394 in.) or less
      Snap Ring Thickness
      Thickness
      1.80 mm (0.0709 in.)
      1.85 mm (0.0728 in.)
      1.90 mm (0.0748 in.)
      1.95 mm (0.0768 in.)
      2.00 mm (0.0787 in.)
      2.05 mm (0.0807 in.)
      2.10 mm (0.0827 in.)
    3. A01DQ1VE02

      Using a snap ring expander, install the snap ring.

      Note

      Do not damage the sliding surface of the bearing.

  6. INSTALL 2ND GEAR NEEDLE ROLLER BEARING


    1. A01DSZME01

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

  7. INSTALL 2ND GEAR


    1. A01DTBDE01

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

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


    1. A01DNT4E01

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

  9. INSTALL REVERSE GEAR


    1. A01DOPJE01

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

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

  10. INSTALL NO. 1 TRANSMISSION CLUTCH HUB


    1. A01DOC2E01

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

      SST
      09316-60011   ( 09316-00041 )

      Note


      • Make sure that the No. 1 synchromesh shifting key positions are aligned with the No. 1 synchronizer ring key grooves.

      • Make sure the 1st gear rotates freely.

    2. Select a snap ring that makes the thrust clearance between the No. 1 clutch hub and snap ring to be within the specification.

      Standard clearance
      0.1 mm (0.00394 in.) or less

      Note

      Do not damage the journal surface of the snap ring.

      Snap Ring Thickness
      Thickness
      2.30 mm (0.0906 in.)
      2.35 mm (0.0925 in.)
      2.40 mm (0.0945 in.)
      2.45 mm (0.0965 in.)
      2.50 mm (0.0984 in.)
      2.55 mm (0.1004 in.)
      2.60 mm (0.1024 in.)
    3. A01DUHZE01

      Using a brass bar and hammer, tap on the snap ring.

  11. INSTALL 1ST GEAR BEARING SPACER


    1. A01DRJXE01

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

  12. INSTALL 1ST GEAR NEEDLE ROLLER BEARING


    1. A01DNX6E02

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

  13. INSTALL 1ST GEAR THRUST WASHER PIN


    1. A01DR7DE01

      Install the thrust washer pin to the output shaft.

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


    1. A01DQF0

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

  15. INSTALL 1ST GEAR


    1. A01DQ55E01

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

  16. INSTALL 1ST GEAR THRUST WASHER


    1. A01DO48E01

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

  17. INSTALL OUTPUT SHAFT CENTER BEARING


    1. A01DS0BE03

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

      SST
      09316-60011   ( 09316-00031 )

      Note

      Install the center bearing so that the snap ring groove of the bearing faces the rear side.

  18. INSTALL 5TH GEAR


    1. A01DTJAE01

      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 splines of the output shaft fit before installing the 5th gear.

      • Make sure face the convex part of the gear faces the front side.

  19. INSPECT 1ST GEAR THRUST CLEARANCE


    1. A01DQ0R

      Using a dial indicator, measure the thrust clearance.

      Standard clearance
      0.20 to 0.45 mm (0.00787 to 0.0177 in.)

      • If the clearance is not as specified, replace the No. 1 synchronizer ring set.

  20. INSPECT 2ND GEAR THRUST CLEARANCE


    1. A01DPIW

      Using a dial indicator, measure the thrust clearance.

      Standard clearance
      0.10 to 0.25 mm (0.00394 to 0.00984 in.)

      • If the clearance is not as specified, replace the No. 1 synchronizer ring set.

  21. INSPECT 3RD GEAR THRUST CLEARANCE


    1. A01DOYME01

      Using a feeler gauge, measure the thrust clearance.

      Standard clearance
      0.10 to 0.25 mm (0.00394 to 0.00984 in.)

      • If the clearance is not as specified, replace the No. 2 synchronizer ring set.

  22. INSPECT 1ST GEAR RADIAL CLEARANCE


    1. A01DPERE01

      Using a dial indicator, measure the radial clearance.

      Standard clearance
      0.020 to 0.073 mm (0.000785 to 0.00287 in.)

      • If the clearance is not as specified, replace the 1st gear needle roller bearing with a new one.

  23. INSPECT 2ND GEAR RADIAL CLEARANCE


    1. A01DQ8NE01

      Using a dial indicator, measure the radial clearance.

      Standard clearance
      0.015 to 0.068 mm (0.000591 to 0.00267 in.)

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

  24. INSPECT 3RD GEAR RADIAL CLEARANCE


    1. A01DOGHE01

      Using a dial indicator, measure the radial clearance.

      Standard clearance
      0.015 to 0.068 mm (0.000591 to 0.00267 in.)

      • If the clearance is not as specified, replace the 3rd gear needle roller bearing with a new one.