OUTPUT SHAFT REASSEMBLY


  1. INSTALL TRANSMISSION CLUTCH HUB NO.2


    1. A003E74E01

      Coat the hub sleeve with gear oil, and install it to the clutch hub.

      Note

      Be sure to set the hub sleeve to the clutch hub in the correct direction.

    2. A003F05

      Install the 3 synchromesh shifting keys to the clutch hub with the 2 synchromesh shifting key springs.

      Tech Tips

      Do not set the openings of the shifting key springs in the same position.

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    1. A003H1Z

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

  3. INSTALL 3RD GEAR


    1. A003DOW

      Coat the 3rd gear with gear oil, and install it to the output shaft.

  4. INSTALL SYNCHRONIZER RING NO.2


    1. A003CX7

      Coat the synchronizer ring with gear oil, and install it to the 3rd gear.

  5. INSTALL TRANSMISSION CLUTCH HUB NO.2


    1. A003HOQ

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

      SST
      09316-60011   ( 09316-00021 )
    2. A003DAB

      Select a clutch hub shaft snap ring that will allow the minimum amount of axial play.

      Standard clearance
      0.1 mm (0.039 in.) or less
      Clutch hub shaft snap ring thickness:
      Mark Thickness: mm (in.)
      C-1 1.75 to 1.80 (0.0689 to 0.0709)
      D 1.80 to 1.85 (0.0709 to 0.0728)
      D-1 1.85 to 1.90 (0.0728 to 0.0748)
      E 1.90 to 1.95 (0.0748 to 0.0768)
      E-1 1.95 to 2.00 (0.0768 to 0.0787)
      F 2.00 to 2.05 (0.0787 to 0.0807)
      F-1 2.05 to 2.10 (0.0807 to 0.0827)
    3. A003CDY

      Using a snap ring expander, install the snap ring.

  6. INSPECT 3RD GEAR THRUST CLEARANCE


    1. A003D6S

      Using a feeler gauge, measure the thrust clearance.

      Standard clearance
      0.10 to 0.25 mm (0.0039 to 0.0098 in.)

  7. INSTALL TRANSMISSION CLUTCH HUB NO.1


    1. A003D54E01

      Coat the reverse gear with gear oil, and install it to the clutch hub.

      Note

      Be sure to set the reverse gear to the clutch hub in the correct direction.

    2. A003F05

      Install 3 synchromesh shifting keys to the clutch hub with the 2 synchromesh shifting key springs.

      Tech Tips

      Do not set the openings of the shifting key springs in the same position.

  8. INSTALL 2ND GEAR NEEDLE ROLLER BEARING


    1. A003EHR

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

  9. INSTALL 2ND GEAR


    1. A003G16

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

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


    1. A003FTM

      Coat the synchronizer ring No.1 with gear oil, and install it to the 2nd gear.

  11. INSTALL TRANSMISSION CLUTCH HUB NO.1


    1. A003BHTE01

      Using SST and a press, press in the clutch hub to the output shaft.

      SST
      09316-60011   ( 09316-00021 )

  12. INSPECT 2ND GEAR THRUST CLEARANCE


    1. A003ICDE02

      Using a dial indicator, measure the thrust clearance.

      Standard clearance
      0.10 to 0.25 mm (0.0039 to 0.0098 in.)

  13. INSTALL SYNCHRONIZER RING NO.1 (for 1st Gear)


    1. A003H9Q

      Coat the synchronizer ring with gear oil, and install it to the clutch hub No.1.

  14. INSTALL 1ST GEAR BEARING INNER RACE LOCK KEY OR BALL


    1. A003CCX

      Coat the lock ball with gear oil, and install it to the output shaft.

  15. INSTALL 1ST GEAR BEARING INNER RACE


    1. A003CT0

      Coat the needle roller bearing with gear oil.

    2. Install the inner lace and the needle roller bearing to the 1st gear.

  16. INSTALL 1ST GEAR


    1. A003BAZ

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

  17. INSTALL OUTPUT SHAFT CENTER BEARING


    1. A003FOAE01

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

      SST
      09316-60011   ( 09316-00021 )

  18. INSPECT 1ST GEAR THRUST CLEARANCE


    1. A003FXH

      Using a dial indicator, measure the thrust clearance.

      Standard clearance
      0.10 to 0.25 mm (0.0039 to 0.0098 in.)

  19. INSTALL 5TH GEAR


    1. A003E3WE01

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

      SST
      09316-60011   ( 09316-00021 )
    2. A003GEA

      Select a snap ring that will allow minimal axial play.

      Standard clearance
      0.1 mm (0.039 in.) or less
      Output shaft bearing shaft snap ring
      Mark Thickness: mm (in.)
      A 2.67 to 2.72 (0.1051 to 0.1071)
      B 2.73 to 2.78 (0.1075 to 0.1094)
      C 2.79 to 2.84 (0.1098 to 0.1118)
      D 2.85 to 2.90 (0.1122 to 0.1141)
      E 2.91 to 2.96 (0.1146 to 0.1165)
      F 2.97 to 3.02 (0.1169 to 0.1189)
      G 3.03 to 3.08 (0.1193 to 0.1213)
      H 3.09 to 3.14 (0.1217 to 0.1236)
      J 3.15 to 3.20 (0.1240 to 0.1260)
      K 3.21 to 3.26 (0.1264 to 0.1283)
      L 3.27 to 3.32 (0.1287 to 0.1307)
    3. A003BUQ

      Using a screwdriver and hammer, tap in the snap ring.

  20. INSTALL SPEEDOMETER DRIVE (MTM) GEAR


    1. A003EAP

      Using a snap ring expander, install the snap ring.

    2. Install the ball.

    3. Install the drive gear.

    4. Using a snap ring expander, install the snap ring.

  21. INSPECT 3RD GEAR RADIAL CLEARANCE


    1. A003GIZ

      Using a dial indicator, measure the radial clearance.

      Standard clearance
      0.008 to 0.0034 mm (0.0003 to 0.00134 in.)

      If the clearance is not as specified, replace the 3rd gear needle roller bearing.

  22. INSPECT 2ND GEAR RADIAL CLEARANCE


    1. A003GUA

      Using a dial indicator, measure the radial clearance.

      Standard clearance
      0.008 to 0.0034 mm (0.0003 to 0.00134 in.)

      If the clearance is not as specified, replace the 2nd gear needle roller bearing.

  23. INSPECT 1ST GEAR RADIAL CLEARANCE


    1. A003I9S

      Using a dial indicator, measure the radial clearance.

      Standard clearance
      0.009 to 0.056 mm (0.0004 to 0.0022 in.)

      If the clearance is not as specified, replace the 1st gear needle roller bearing.