OUTPUT SHAFT REASSEMBLY

PROCEDURE


  1. INSTALL NEEDLE ROLLER BEARING


    1. A004SAM

      Coat the needle roller bearing with gear oil, and install it into the No. 2 output shaft.

  2. INSTALL REVERSE DRIVEN GEAR


    1. A004RGF

      Coat the reverse driven gear with gear oil, and install it into the No. 2 output shaft.

  3. INSTALL NO. 4 TRANSMISSION CLUTCH HUB


    1. A004TAPE05
      Text in Illustration
      *1 Hub Sleeve
      *2 Reverse Driven Gear Synchronizer Ring
      *3 Shifting Key
      *4 Key Spring
      *5 Clutch Hub
      *6 Claw

      Install the key spring and 2 shifting keys to the clutch hub.

      Tech Tips


      • Install the shifting key with the grooves on the clutch hub side.

      • Install the key spring with the claw on the clutch hub side.

      • Refer to the illustration when installing the key spring and shifting keys.

    2. Install the hub sleeve to the reverse driven gear as shown in the illustration.

    3. A004NBVE01

      Coat the No. 4 transmission clutch hub with gear oil, and install it into the No. 2 output shaft.

    4. Using SST and a press, press in the reverse gear and No. 4 transmission clutch hub into the No. 2 output shaft.

      SST
      09308-14010

      Note

      After installation, make sure that the gear and synchronizer ring move smoothly.

      Tech Tips

      Make sure that the protruding part on the synchronizer ring is fitted into the groove of the clutch hub.

  4. INSTALL SHAFT SNAP RING


    1. A004RYFE01
      Text in Illustration
      *1 Mark

      Select a new snap ring, using the table below, that makes the thrust clearance of the No. 4 transmission clutch hub less than 0.1 mm (0.00394 in.).

      Standard shaft snap ring thickness
      Mark Specified Condition Mark Specified Condition
      A 2.25 to 2.30 mm (0.0886 to 0.0906 in.) E 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
      B 2.30 to 2.35 mm (0.0906 to 0.0925 in.) F 2.50 to 2.55 mm (0.0984 to 0.100 in.)
      C 2.35 to 2.40 mm (0.0925 to 0.0945 in.) G 2.55 to 2.60 mm (0.100 to 0.102 in.)
      D 2.40 to 2.45 mm (0.0945 to 0.0965 in.) H 2.60 to 2.65 mm (0.102 to 0.104 in.)
    2. A004NIE

      Using a brass bar and hammer, tap the snap ring onto the No. 2 output shaft.

  5. INSPECT REVERSE DRIVEN GEAR THRUST CLEARANCE

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  6. INSPECT REVERSE DRIVEN GEAR RADIAL CLEARANCE

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  7. INSTALL 5TH DRIVEN GEAR


    1. A004R4Z

      Install the output shaft spacer into the No. 2 output shaft.

    2. A004OYU

      Coat the 2 pieces of the needle roller bearing with gear oil, and install them into the No. 2 output shaft.

    3. A004Q83

      Install the output shaft spacer into the No. 2 output shaft.

    4. A004RL1

      Coat the 5th driven gear with gear oil, and install it into the No. 2 output shaft.

  8. INSTALL NO. 3 TRANSMISSION CLUTCH HUB


    1. A004U97

      Apply of gear oil to the sleeve and hub.

    2. Install the hub sleeve to the clutch hub.

    3. Install the 3 shifting keys to the clutch hub.

    4. Install the 3 shifting key springs to the clutch hub.

    5. Place the 3 balls in the holes of the shifting keys, and install the hub sleeve while pushing in the balls.

      Note

      Take care to prevent the balls from scattering.

    6. A004NSUE01

      Coat the 5th driven gear synchronizer ring with gear oil, and install it to the 5th driven gear.

    7. Using SST and a press, press in the No. 3 transmission clutch hub to the No. 2 output shaft.

      SST
      09308-14010

      Tech Tips

      Make sure that the protruding part on the synchronizer ring is fitted into the groove of the clutch hub.

      Note

      After installation, make sure that the gear and synchronizer ring move smoothly.

  9. INSTALL SHAFT SNAP RING


    1. A004MN3E01
      Text in Illustration
      *1 Mark

      Select a new snap ring, using the table below, that makes the thrust clearance of the No. 3 transmission clutch hub less than 0.1 mm (0.00394 in.).

      Standard shaft snap ring thickness
      Mark Specified Condition Mark Specified Condition
      1 2.25 to 2.30 mm (0.0886 to 0.0906 in.) 4 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
      2 2.30 to 2.35 mm (0.0906 to 0.0925 in.) 5 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
      3 2.35 to 2.40 mm (0.0925 to 0.0945 in.) 6 2.50 to 2.55 mm (0.0984 to 0.100 in.)
    2. A004UE8

      Using a brass bar and hammer, tap the snap ring onto the No. 2 output shaft.

  10. INSPECT 5TH DRIVEN GEAR THRUST CLEARANCE

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  11. INSPECT 5TH DRIVEN GEAR RADIAL CLEARANCE

    Click here

  12. INSTALL 6TH DRIVEN GEAR


    1. A004O3V

      Install the spacer into the No. 2 output shaft.

    2. A004TUZ

      Coat the 2 pieces of the needle roller bearing with gear oil, and install them into the No. 2 output shaft.

    3. A004OMV

      Coat the 6th gear synchronizer ring with gear oil, and install it into the transmission clutch hub.

    4. A004RK2

      Coat the 6th driven gear with gear oil, and install it into the No. 2 output shaft.

  13. INSTALL NO. 2 OUTPUT SHAFT REAR BEARING


    1. A004P3AE01

      Using SST and a press, press in the No. 2 output shaft rear bearing to the No. 2 output shaft.

      SST
      09710-04071

      Note

      After installation, make sure that the gear and synchronizer ring move smoothly.

  14. INSTALL NO. 2 OUTPUT SHAFT BEARING SNAP RING


    1. A004PW2E01
      Text in Illustration
      *1 Mark

      Select a new snap ring, using the table below, that makes the thrust clearance of the 6th gear less than 0.1 mm (0.00394 in.).

      Standard No. 2 output shaft bearing snap ring thickness
      Mark Specified Condition Mark Specified Condition
      B 1.85 to 1.90 mm (0.0728 to 0.0748 in.) 0 2.05 to 2.10 mm (0.0807 to 0.0827 in.)
      C 1.90 to 1.95 mm (0.0748 to 0.0768 in.) 1 2.10 to 2.15 mm (0.0827 to 0.0846 in.)
      D 1.95 to 2.00 mm (0.0768 to 0.0787 in.) 2 2.15 to 2.20 mm (0.0846 to 0.0866 in.)
      E 2.00 to 2.05 mm (0.0787 to 0.0807 in.) - -
    2. A004RY7

      Using a snap ring expander, install the snap ring onto the No. 2 output shaft.

  15. INSPECT 6TH DRIVEN GEAR THRUST CLEARANCE

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  16. INSPECT 6TH DRIVEN GEAR RADIAL CLEARANCE

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  17. INSTALL NO. 2 OUTPUT SHAFT FRONT BEARING


    1. A004O3RE01

      Using SST and a press, press in the No. 2 output shaft front bearing into the No. 2 output shaft.

      SST
      09309-37010
      09506-30012

  18. INSTALL OUTPUT SHAFT FRONT BEARING


    1. A004PVOE01

      Using SST and a press, press in the output shaft front bearing into the No. 1 output shaft.

      SST
      09309-14040

  19. INSTALL OUTPUT SHAFT FRONT BEARING SHAFT SNAP RING


    1. A004QGB

      Using a snap ring expander, install a new snap ring into the No. 1 output shaft.

  20. INSTALL 1ST DRIVEN GEAR


    1. A004MR5

      Coat the needle roller bearing with gear oil, and install it into the No. 1 output shaft.

    2. A004MM5

      Coat the 1st driven gear with gear oil, and install it into the No. 1 output shaft.

  21. INSTALL NO. 1 TRANSMISSION CLUTCH HUB


    1. A004OLF

      Apply of gear oil to the sleeve and hub.

    2. Install the hub sleeve to the clutch hub.

    3. Install the 3 shifting keys to the clutch hub.

    4. Install the 3 shifting key springs to the clutch hub.

    5. Place the 3 balls in the holes of the shifting keys, and install the hub sleeve while pushing in the balls.

      Note

      Take care to prevent the balls from scattering.

    6. A004RLGE04

      Coat the 3 pieces of the 1st driven gear synchronizer ring set with gear oil, and install them to the 1st driven gear.

    7. Using SST and a press, press in the No. 1 transmission hub sleeve to the No. 1 output shaft.

      SST
      09726-40010

      Note

      After installation, make sure that the gear and synchronizer ring move smoothly.

      Tech Tips

      Make sure that the protruding part on the synchronizer ring is fitted into the groove of the clutch hub.

  22. INSTALL 2ND DRIVEN GEAR SYNCHRONIZER RING SET


    1. A004NPF

      Coat the 3 pieces of the 2nd driven gear synchronizer ring set with gear oil, and install them to the No. 1 output shaft.

  23. INSTALL SYNCHROMESH SHIFTING KEY BALL


    1. A004RWDE01
      Text in Illustration
      *1 Magnet Hand

      Install the key ball onto the No. 1 output shaft.

  24. INSTALL NEEDLE ROLLER BEARING


    1. A004TC6

      Coat the needle roller bearing with gear oil, and install it into the No. 1 output shaft.

  25. INSTALL 2ND DRIVEN GEAR


    1. A004OJB

      Coat the 2nd driven gear with gear oil, and install it into the No. 1 output shaft.

  26. INSTALL INNER 2ND DRIVEN GEAR BEARING RACE


    1. A004SZ4

      Align the groove of the inner 2nd driven gear bearing race with the ball, and install it.

  27. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A004QXKE01
      Text in Illustration
      *1 Mark

      Select a new snap ring, using the table below, that makes the thrust clearance of the 2nd gear less than 0.1 mm (0.00394 in.).

      Standard output shaft bearing shaft snap ring thickness
      Mark Specified Condition Mark Specified Condition
      A 2.25 to 2.30 mm (0.0886 to 0.0906 in.) E 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
      B 2.30 to 2.35 mm (0.0906 to 0.0925 in.) F 2.50 to 2.55 mm (0.0984 to 0.100 in.)
      C 2.35 to 2.40 mm (0.0925 to 0.0945 in.) G 2.55 to 2.60 mm (0.100 to 0.102 in.)
      D 2.40 to 2.45 mm (0.0945 to 0.0965 in.) H 2.60 to 2.65 mm (0.102 to 0.104 in.)
    2. A004T9X

      Using a snap ring expander, install the snap ring into the No. 1 output shaft.

      Note

      Do not damage the journal surface of the No. 1 output shaft.

  28. INSPECT 1ST DRIVEN GEAR THRUST CLEARANCE

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  29. INSPECT 1ST DRIVEN GEAR RADIAL CLEARANCE

    Click here

  30. INSPECT 2ND DRIVEN GEAR THRUST CLEARANCE

    Click here

  31. INSPECT 2ND DRIVEN GEAR RADIAL CLEARANCE

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  32. INSTALL 4TH DRIVEN GEAR


    1. A004PQC

      Install the spacer into the No. 1 output shaft.

    2. A004U3A

      Coat the 2 pieces of the 4th driven gear needle roller bearing with gear oil, and install them into the No. 1 output shaft.

    3. A004NT0

      Coat the 4th driven gear with gear oil, and install it into the No. 1 output shaft.

  33. INSTALL NO. 2 TRANSMISSION CLUTCH HUB


    1. A004OQN

      Apply of gear oil to the sleeve and hub.

    2. Install the hub sleeve to the clutch hub.

    3. Install the 3 shifting keys to the clutch hub.

    4. Install the 3 shifting key springs to the clutch hub.

    5. Place the 3 balls in the holes of the shifting keys, and install the hub sleeve while pushing in the balls.

      Note

      Take care to prevent the balls from scattering.

    6. Coat the 3 pieces of the 4th driven gear synchronizer ring set with gear oil, and install them into the 4th driven gear.

    7. A004N5RE01

      Using SST and a press, press in the No. 2 transmission hub sleeve to the No. 1 output shaft.

      SST
      09309-14010

      Tech Tips

      Make sure that the protruding part on the synchronizer ring is fitted into the groove of the clutch hub.

      Note

      After installation, make sure that the gear and synchronizer ring move smoothly.

  34. INSTALL SHAFT SNAP RING


    1. A004SMIE01
      Text in Illustration
      *1 Mark

      Select a new snap ring, using the table below, that makes the thrust clearance of the No. 2 transmission clutch hub less than 0.1 mm (0.00394 in.).

      Standard shaft snap ring thickness
      Mark Specified Condition Mark Specified Condition
      1 2.25 to 2.30 mm (0.0886 to 0.0906 in.) 4 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
      2 2.30 to 2.35 mm (0.0906 to 0.0925 in.) 5 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
      3 2.35 to 2.40 mm (0.0925 to 0.0945 in.) 6 2.50 to 2.55 mm (0.0984 to 0.100 in.)
    2. A004MXN

      Using a brass bar and hammer, tap the snap ring into the No. 1 output shaft.

  35. INSPECT 4TH DRIVEN GEAR THRUST CLEARANCE

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  36. INSPECT 4TH DRIVEN GEAR RADIAL CLEARANCE

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  37. INSTALL 3RD DRIVEN GEAR


    1. A004R5U

      Coat the 3rd driven gear synchronizer ring set with gear oil, and install it into the No. 1 output shaft.

    2. A004OFG

      Coat the needle roller bearing with gear oil, and install it into the No. 1 output shaft.

    3. A004Q1B

      Install the spacer into the No. 1 output shaft.

    4. A004P5N

      Coat the 3rd driven gear with gear oil, and install it into the No. 1 output shaft.

  38. INSTALL OUTPUT SHAFT FRONT BEARING


    1. A004PLVE02

      Using SST and a press, press in the output shaft front bearing into the No. 1 output shaft.

      SST
      09308-14010

      Tech Tips

      When pressing in the bearing, apply force to only the inner race. Do not apply force to the seal.

      Note

      After installation, make sure that the gear and synchronizer ring move smoothly.

  39. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A004TSGE01
      Standard output shaft bearing snap ring thickness
      Mark Specified Condition Mark Specified Condition
      B 1.85 to 1.90 mm (0.0728 to 0.0748 in.) 0 2.05 to 2.10 mm (0.0807 to 0.0827 in.)
      C 1.90 to 1.95 mm (0.0748 to 0.0768 in.) 1 2.10 to 2.15 mm (0.0827 to 0.0846 in.)
      D 1.95 to 2.00 mm (0.0768 to 0.0787 in.) 2 2.15 to 2.20 mm (0.0846 to 0.0866 in.)
      E 2.00 to 2.05 mm (0.0787 to 0.0807 in.) - -
      Text in Illustration
      *1 Mark

      Select a new snap ring, using the table below, that makes the thrust clearance of the output shaft bearing less than 0.1 mm (0.00394 in.).

      Standard output shaft bearing snap ring thickness
      Mark Specified Condition Mark Specified Condition
      B 1.85 to 1.90 mm (0.0728 to 0.0748 in.) 0 2.05 to 2.10 mm (0.0807 to 0.0827 in.)
      C 1.90 to 1.95 mm (0.0748 to 0.0768 in.) 1 2.10 to 2.15 mm (0.0827 to 0.0846 in.)
      D 1.95 to 2.00 mm (0.0768 to 0.0787 in.) 2 2.15 to 2.20 mm (0.0846 to 0.0866 in.)
      E 2.00 to 2.05 mm (0.0787 to 0.0807 in.) - -
      Text in Illustration
      *1 Mark
    2. A004PSC
      Text in Illustration
      *1 Mark

      Using a snap ring expander, install the snap ring onto the No. 1 output shaft.

  40. INSPECT 3RD DRIVEN GEAR THRUST CLEARANCE

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  41. INSPECT 3RD DRIVEN GEAR RADIAL CLEARANCE

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