OUTPUT SHAFT REASSEMBLY

PROCEDURE


  1. INSTALL NO. 2 TRANSMISSION HUB SLEEVE


    1. A01XCFG

      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. A01XIUK

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

  3. INSTALL 3RD GEAR


    1. A01XEBC

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

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


    1. A01XKWR

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

  5. INSTALL NO. 2 TRANSMISSION CLUTCH HUB


    1. A01XMHYE02

      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. A01XFCD

      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. A01XJKV

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

  7. INSTALL 2ND GEAR


    1. A01XFKR

      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. A01XG9Y

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

  9. INSTALL REVERSE GEAR


    1. A01XKZM

      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. A01XDAPE01

      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. A01XL1I

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

  11. INSTALL 1ST GEAR BEARING SPACER


    1. A01XLXP

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

  12. INSTALL 1ST GEAR NEEDLE ROLLER BEARING


    1. A01XH8L

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

  13. INSTALL 1ST GEAR THRUST WASHER PIN


    1. A01XHQF

      Install the thrust washer pin to the output shaft.

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


    1. A01XD33

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

  15. INSTALL 1ST GEAR


    1. A01XDSC

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

  16. INSTALL 1ST GEAR THRUST WASHER


    1. A01XCKN

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

  17. INSTALL OUTPUT SHAFT CENTER BEARING


    1. A01XCQEE06

      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. A01XHZJE01

      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

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  20. INSPECT 2ND GEAR THRUST CLEARANCE

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  21. INSPECT 3RD GEAR THRUST CLEARANCE

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  22. INSPECT 1ST GEAR RADIAL CLEARANCE

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  23. INSPECT 2ND GEAR RADIAL CLEARANCE

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  24. INSPECT 3RD GEAR RADIAL CLEARANCE

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