OUTPUT SHAFT REASSEMBLY

PROCEDURE


  1. INSTALL FRONT OUTPUT SHAFT BEARING


    1. A01LUYRN01

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

      SST
      09309-14040
      09612-22011

  2. INSTALL 1ST GEAR BUSHING


    1. A01M35A

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

  3. INSTALL 1ST GEAR NEEDLE ROLLER BEARING


    1. A01M0JJ

      Coat the 1st gear needle roller bearing with gear oil and install it to the output shaft.

  4. INSTALL 1ST GEAR


    1. A01LZW9

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

      Note

      Install the 1st gear as shown in the illustration.

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


    1. Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring and outer ring) with gear oil.

    2. A01M20V

      Install the inner ring to the 1st gear.

    3. Install the middle ring to the 1st gear.

      Note

      Engage the claws of the middle ring to the grooves of the 1st gear.

    4. Install the outer ring to the 1st gear.

      Note

      Align the claws of the inner ring with the grooves of the outer ring before installing the outer ring.

  6. INSTALL NO. 1 TRANSMISSION CLUTCH HUB


    1. A01LX61

      Install the No. 1 transmission clutch hub to the output shaft.

      Note

      Align the cutouts of the No. 1 transmission clutch hub with the protrusions of the outer ring as shown in the illustration.

  7. INSTALL NO. 1 SYNCHROMESH SHIFTING KEY


    1. A01M186

      Install the 3 No. 1 synchromesh shifting keys to the No. 1 transmission clutch hub.

  8. INSTALL REVERSE GEAR


    1. Coat the reverse gear and No. 1 transmission clutch hub with gear oil.

    2. A01LZGB

      Install the reverse gear to the No. 1 transmission clutch hub.

      Note

      Install the reverse gear as shown in the illustration.

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


    1. Coat the No. 1 synchronizer ring set (inner ring, middle ring and outer ring) with gear oil.

    2. A01M20P

      Install the outer ring to the No. 1 transmission clutch hub.

      Note

      Align the protrusion of the outer ring with the cutout of the No. 1 transmission clutch hub before installing the outer ring.

    3. A01LVDM

      Install the middle ring to the outer ring.

    4. A01M03HC09
      *a Inner Ring
      *b Outer Ring
      *c Cutout

      Install the inner ring to the middle ring.

      Note

      Align the cutouts of the outer ring with the protrusions of the inner ring before installing the inner ring.

  10. INSTALL INNER 2ND GEAR BEARING RACE


    1. A01LX93

      Coat the inner 2nd gear bearing race with gear oil and install it to the output shaft.

  11. INSTALL 2ND GEAR NEEDLE ROLLER BEARING


    1. A01LY6Z

      Coat the 2nd gear needle roller bearing with gear oil and install it to the output shaft.

  12. INSTALL 2ND GEAR


    1. A01M038C08
      *a Claw
      *b Groove

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

      Note

      Align the claws of the middle ring with the grooves of the 2nd gear before installing the 2nd gear.

  13. INSTALL 3RD DRIVEN GEAR


    1. A01M2CTN05

      Using SST and a press, install the 3rd driven gear to the output shaft.

      SST
      09316-60011   ( 09316-00011 )

  14. INSTALL OUTPUT GEAR SPACER


    1. A01LYSF

      Install the output gear spacer to the output shaft.

  15. INSTALL 4TH DRIVEN GEAR


    1. A01M140N03

      Using SST and a press, install the 4th driven gear to the output shaft.

      SST
      09309-37010
      09502-24010

  16. INSTALL 5TH DRIVEN GEAR


    1. A01LVQFN05

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

      SST
      09316-60011   ( 09316-00011 )

  17. INSTALL OUTPUT GEAR SPACER


    1. A01LVOM

      Install the output gear spacer to the output shaft.

  18. INSTALL 6TH DRIVEN GEAR


    1. A01M2S1N05

      Using SST and a press, install the 6th driven gear to the output shaft.

      SST
      09226-10010

  19. INSTALL REAR OUTPUT SHAFT BEARING


    1. A01LXCAN04

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

      SST
      09608-04031

  20. INSPECT 2ND GEAR RADIAL CLEARANCE

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  21. INSPECT 1ST GEAR RADIAL CLEARANCE

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  22. INSPECT 2ND GEAR THRUST CLEARANCE

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  23. INSPECT 1ST GEAR THRUST CLEARANCE

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