OUTPUT SHAFT REASSEMBLY


  1. INSTALL TRANSMISSION HUB SLEEVE NO.2


    1. A003BD8

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

      Note

      Make sure that the transmission hub sleeve No.2 and transmission clutch hub No.2 are oriented in the correct direction.

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

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    1. A003GZM

      Apply gear oil to the 3rd gear needle roller bearing, and install it onto the output shaft.

  3. INSTALL 3RD GEAR


    1. A003HIZE02

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

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


    1. A003C2YE02

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

  5. INSTALL TRANSMISSION CLUTCH HUB NO.2


    1. A003BKQE01

      Using SST, install the transmission clutch hub No.2 onto the output shaft.

      SST
      09608-06041

      Note


      • Install it with the synchronizer ring No.2 grooves aligned with the shifting key positions.

      • Make sure that the 3rd gear rotates smoothly.

    2. A003H7M

      Select a clutch hub set shaft snap ring so that the clearance between the transmission clutch hub No.2 and shaft snap ring is within the specified values. Then install it onto the output shaft.

      Standard clearance
      0.1 mm or less

      Note

      Do not damage the sliding surface of the bearing.

      Mark Thickness mm (in.)
      A 1.80 to 1.85 mm (0.0709 to 0.0728 in.)
      B 1.85 to 1.90 mm (0.0728 to 0.0748 in.)
      C 1.90 to 1.95 mm (0.0748 to 0.0768 in.)
      D 1.95 to 2.00 mm (0.0768 to 0.0787 in.)
      E 2.00 to 2.05 mm (0.0787 to 0.0807 in.)
      F 2.05 to 2.10 mm (0.0807 to 0.0827 in.)
      G 2.10 to 2.15 mm (0.0827 to 0.0846 in.)

  6. INSTALL 2ND GEAR NEEDLE ROLLER BEARING


    1. A003HMQ

      Apply gear oil to the 2nd gear needle roller bearing, and install it onto the output shaft.

  7. INSTALL 2ND GEAR


    1. A003DKNE02

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

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


    1. A003E8X

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

  9. INSTALL REVERSE GEAR


    1. A003B2M

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

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

  10. INSTALL TRANSMISSION CLUTCH HUB NO.1


    1. A003B8ZE01

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

      SST
      09316-60011   ( 09316-00041 )

      Note


      • Perform installation making sure that the synchronizer ring No.1 grooves and synchromesh shifting keys No.1 are in place.

      • Make sure that the 1st gear rotates smoothly.

    2. A003GKO

      Select a bearing shaft snap ring so that the clearance between the transmission clutch hub No.1 and bearing shaft snap ring is within the specified values. Then install it onto the output shaft.

      Standard clearance
      0.1 mm (0.039 in.) or less

      Note

      Do not damage the sliding surface of the bearing.

      Mark Thickness mm (in.)
      A 2.30 to 2.35 mm (0.0906 to 0.0925 in.)
      B 2.35 to 2.40 mm (0.0925 to 0.0945 in.)
      C 2.40 to 2.45 mm (0.0945 to 0.0965 in.)
      D 2.45 to 2.50 mm (0.0965 to 0.0984 in.)
      E 2.50 to 2.55 mm (0.0984 to 0.1004 in.)
      F 2.55 to 2.60 mm (0.1004 to 0.1024 in.)
      G 2.60 to 2.65 mm (0.1024 to 0.1043 in.)

  11. INSTALL 1ST GEAR BEARING SPACER


    1. A003BCP

      Apply gear oil to the 1st gear bearing spacer, and install it onto the output shaft.

  12. INSTALL 1ST GEAR NEEDLE ROLLER BEARING


    1. A003HI3

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

  13. INSTALL 1ST GEAR THRUST WASHER PIN


    1. A003GRB

      Install the 1st gear thrust washer pin onto the output shaft.

  14. INSTALL SYNCHRONIZER RING NO.1 (for 1st Gear (2TR-FE))


    1. A003DNS

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

  15. INSTALL SYNCHRONIZER RING SET NO.1 (for 1st Gear (2KD-FTV))


    1. A003G1P

      Apply gear oil to the synchronizer ring set No.1, and install it to the 1st gear.

  16. INSTALL 1ST GEAR


    1. A003GZXE02

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

  17. INSTALL 1ST GEAR THRUST WASHER


    1. A003DW1E02

      Apply gear oil to the 1st gear thrust washer, and install it onto the output shaft.

  18. INSTALL OUTPUT SHAFT CENTER BEARING


    1. A003F1SE01

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

      SST
      09316-60011   ( 09316-00031 )

      Note

      Install it with the snap ring groove of the bearing facing to the rear side.

  19. INSTALL 5TH GEAR


    1. A003D3EE01

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

      SST
      09316-60011   ( 09316-00031 )

      Note


      • Check that the 5th gear is fitted into the spline of the output shaft before installing.

      • Face the convex part of the gear to the front side.

  20. INSPECT 1ST GEAR THRUST CLEARANCE


    1. A003HB5

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

      Standard clearance
      0.20 to 0.45 mm (0.0079 to 0.0177 in.)

  21. INSPECT 2ND GEAR THRUST CLEARANCE


    1. A003ICDE11

      Using a dial indicator, measure the thrust clearance of the 2nd gear.

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

  22. INSPECT 3RD GEAR THRUST CLEARANCE


    1. A003IC1E02

      Using a feeler gauge, measure the thrust clearance of the 3rd gear.

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

  23. INSPECT 1ST GEAR RADIAL CLEARANCE


    1. A003D29

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

      Standard clearance
      0.020 to 0.073 mm (0.0008 to 0.0029 in.)

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

  24. INSPECT 2ND GEAR RADIAL CLEARANCE


    1. A003DSD

      Using a dial indicator, measure the radial clearance of the 2nd gear.

      Standard clearance
      0.015 to 0.068mm (0.0006 to 0.0027 in.)

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

  25. INSPECT 3RD GEAR RADIAL CLEARANCE


    1. A003I8C

      Using a dial indicator, measure the radial clearance of the 3rd gear.

      Standard clearance
      0.015 to 0.068 mm (0.0006 to 0.0027 in.)

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