OUTPUT SHAFT REASSEMBLY

PROCEDURE


  1. INSTALL NEEDLE ROLLER BEARING


    1. A012FDT

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

  2. INSTALL REVERSE DRIVEN GEAR


    1. A012ISA

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

  3. INSTALL NO. 4 TRANSMISSION CLUTCH HUB


    1. A012MBEC01
      *1 No. 4 Transmission Hub Sleeve
      *2 Shifting Key
      *3 Reverse Driven Gear Synchronizer Ring
      *4 Key Spring
      *5 No. 4 Transmission Clutch Hub
      *a Claw

      Install the reverse driven gear synchronizer ring, key spring and shifting key to the No. 4 transmission clutch hub.

      Tech Tips


      • Install the shifting key with the grooves on the No. 4 transmission clutch hub side.

      • Install the key spring with the claw on the No. 4 transmission clutch hub side.

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

    2. Install the No. 4 transmission hub sleeve to the reverse driven gear as shown in the illustration.

    3. A012M7ZN01

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

    4. Using SST and a press, install the reverse driven gear and No. 4 transmission clutch hub to 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 reverse driven gear synchronizer ring is fitted into the groove of the No. 4 transmission clutch hub.

  4. INSTALL SHAFT SNAP RING


    1. A012HDRC01
      *a Mark

      Select a new shaft 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.).

      Shaft Snap Ring Thickness:
      Mark Thickness mm (in.) Mark Thickness mm (in.)
      A 2.25 to 2.30 (0.0886 to 0.0906) E 2.45 to 2.50 (0.0965 to 0.0984)
      B 2.30 to 2.35 (0.0906 to 0.0925) F 2.50 to 2.55 (0.0984 to 0.1004)
      C 2.35 to 2.40 (0.0925 to 0.0945) G 2.55 to 2.60 (0.1004 to 0.1024)
      D 2.40 to 2.45 (0.0945 to 0.0965) H 2.60 to 2.65 (0.1024 to 0.1043)
    2. A012LBR

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

  5. INSPECT REVERSE DRIVEN GEAR THRUST CLEARANCE

    Click here

  6. INSPECT REVERSE DRIVEN GEAR RADIAL CLEARANCE

    Click here

  7. INSTALL 5TH DRIVEN GEAR


    1. A012HC5

      Install the spacer to the No. 2 output shaft.

    2. A012LLE

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

    3. A012IQ5

      Install the spacer to the No. 2 output shaft.

    4. A012FGW

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

  8. INSTALL NO. 3 TRANSMISSION CLUTCH HUB


    1. A012JX3

      Apply gear oil to the No. 3 transmission hub sleeve and No. 3 transmission clutch hub.

    2. Install the No. 3 transmission hub sleeve to the No. 3 transmission clutch hub.

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

    4. Install the 3 synchronizer shifting key springs to the No. 3 transmission clutch hub.

    5. Place the balls in the holes of the No. 1 synchromesh shifting keys and install the No. 3 transmission hub sleeve while pushing in the balls.

      Note

      Take care to prevent the balls from scattering.

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

    7. A012I88N01

      Using SST and a press, install the No. 3 transmission clutch hub to 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 5th driven gear synchronizer ring is fitted into the groove of the No. 3 transmission clutch hub.

  9. INSTALL SHAFT SNAP RING


    1. A012LYQC02
      *a Mark

      Select a new shaft 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.).

      Shaft Snap Ring Thickness:
      Mark Thickness mm (in.) Mark Thickness mm (in.)
      1 2.25 to 2.30 (0.0886 to 0.0906) 4 2.40 to 2.45 (0.0945 to 0.0965)
      2 2.30 to 2.35 (0.0906 to 0.0925) 5 2.45 to 2.50 (0.0965 to 0.0984)
      3 2.35 to 2.40 (0.0925 to 0.0945) 6 2.50 to 2.55 (0.0984 to 0.1004)
    2. A012GRS

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

  10. INSPECT 5TH DRIVEN GEAR THRUST CLEARANCE

    Click here

  11. INSPECT 5TH DRIVEN GEAR RADIAL CLEARANCE

    Click here

  12. INSTALL 6TH DRIVEN GEAR


    1. A012IGD

      Install the spacer to the No. 2 output shaft.

    2. A012K9A

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

    3. A012IH6

      Coat the 6th driven gear synchronizer ring with gear oil and install it to the No. 3 transmission clutch hub.

    4. A012HRI

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

  13. INSTALL NO. 2 OUTPUT SHAFT REAR BEARING


    1. A012KG2N01

      Using SST and a press, install 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. A012G59C01
      *a Mark

      Select a new No. 2 output shaft bearing snap ring, using the table below, that makes the thrust clearance of the No. 2 output shaft rear bearing less than 0.1 mm (0.00394 in.).

      No. 2 Output Shaft Bearing Snap Ring Thickness:
      Mark Thickness mm (in.) Mark Thickness mm (in.)
      B 1.85 to 1.90 (0.0728 to 0.0748) 0 2.05 to 2.10 (0.0807 to 0.0827)
      C 1.90 to 1.95 (0.0748 to 0.0768) 1 2.10 to 2.15 (0.0827 to 0.0846)
      D 1.95 to 2.00 (0.0768 to 0.0787) 2 2.15 to 2.20 (0.0846 to 0.0866)
      E 2.00 to 2.05 (0.0787 to 0.0807) - -
    2. A012M8F

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

  15. INSPECT 6TH DRIVEN GEAR THRUST CLEARANCE

    Click here

  16. INSPECT 6TH DRIVEN GEAR RADIAL CLEARANCE

    Click here

  17. INSTALL NO. 2 OUTPUT SHAFT FRONT BEARING


    1. A012L4AN01

      Using SST and a press, install the No. 2 output shaft front bearing to the No. 2 output shaft.

      SST
      09309-37010
      09506-30012

  18. INSTALL OUTPUT SHAFT FRONT BEARING INNER RACE


    1. A012NEZN01

      Using SST and a press, install the output shaft front bearing inner race to the No. 1 output shaft.

      SST
      09309-14040

  19. INSTALL OUTPUT SHAFT FRONT BEARING SHAFT SNAP RING


    1. A012N9O

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

  20. INSTALL 1ST DRIVEN GEAR


    1. A012HB9

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

    2. A012LX7C04
      *a Inner Ring

      Install the inner ring to the 1st driven gear.

    3. A012JX1C03
      *a Middle Ring

      Install the middle ring to the 1st driven gear.

    4. A012KIDC03
      *a Outer Ring

      Install the outer ring to the 1st driven gear.

    5. A012FIE

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

  21. INSTALL NO. 1 TRANSMISSION CLUTCH HUB


    1. A012F7A

      Apply gear oil to the No. 1 transmission hub sleeve and No. 1 transmission clutch hub.

    2. Install the No. 1 transmission hub sleeve to the No. 1 transmission clutch hub.

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

    4. Install the 3 synchronizer shifting key springs to the No. 1 transmission clutch hub.

    5. Place the balls in the holes of the No. 1 synchromesh shifting keys and install the No. 1 transmission hub sleeve while pushing in the balls.

      Note

      Take care to prevent the balls from scattering.

    6. Coat the 1st driven gear synchronizer ring set with gear oil.

    7. A012GWWN01

      Using SST and a press, install 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 1st driven gear synchronizer ring set is fitted into the groove of the No. 1 transmission clutch hub.

  22. INSTALL 2ND DRIVEN GEAR SYNCHRONIZER RING SET


    1. A012HJ7C03
      *a Inner Ring

      Coat the 2nd driven gear synchronizer ring set with gear oil.

    2. Install the inner ring to the 2nd driven gear.

    3. A012LIYC03
      *a Middle Ring

      Install the middle ring to the 2nd driven gear.

    4. A012HERC03
      *a Outer Ring

      Install the outer ring to the 2nd driven gear.

  23. INSTALL SYNCHROMESH SHIFTING KEY BALL


    1. A012J04

      Install the synchromesh shifting key ball to the No. 1 output shaft.

  24. INSTALL NEEDLE ROLLER BEARING


    1. A012GPI

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

  25. INSTALL 2ND DRIVEN GEAR


    1. A012M00

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

  26. INSTALL 2ND DRIVEN GEAR BEARING INNER RACE


    1. A012LM9

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

  27. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A012KARC01
      *a Mark

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

      Output Shaft Bearing Shaft Snap Ring Thickness:
      Mark Thickness mm (in.) Mark Thickness mm (in.)
      A 2.25 to 2.30 (0.0886 to 0.0906) E 2.45 to 2.50 (0.0965 to 0.0984)
      B 2.30 to 2.35 (0.0906 to 0.0925) F 2.50 to 2.55 (0.0984 to 0.1004)
      C 2.35 to 2.40 (0.0925 to 0.0945) G 2.55 to 2.60 (0.1004 to 0.1024)
      D 2.40 to 2.45 (0.0945 to 0.0965) H 2.60 to 2.65 (0.1024 to 0.1043)
    2. A012MS8

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

      Tech Tips

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

  28. INSPECT 1ST DRIVEN GEAR THRUST CLEARANCE

    Click here

  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

    Click here

  32. INSTALL 4TH DRIVEN GEAR


    1. A012JEZ

      Install the spacer to the No. 1 output shaft.

    2. A012IXW

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

    3. A012F9KC03
      *a Inner Ring

      Install the inner ring to the 4th driven gear.

    4. A012G4OC04
      *a Middle Ring

      Install the middle ring to the 4th driven gear.

    5. A012KF2C03
      *a Outer Ring

      Install the outer ring to the 4th driven gear.

    6. A012L6W

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

  33. INSTALL NO. 2 TRANSMISSION CLUTCH HUB


    1. A012KD8

      Apply gear oil to the No. 2 transmission hub sleeve and No. 2 transmission clutch hub.

    2. Install the No. 2 transmission hub sleeve to the No. 2 transmission clutch hub.

    3. Install the 3 No. 1 synchromesh shifting keys to the No. 2 transmission clutch hub.

    4. Install the 3 synchronizer shifting key springs to the No. 2 transmission clutch hub.

    5. Place the balls in the holes of the No. 1 synchromesh shifting keys and install the No. 2 transmission hub sleeve while pushing in the balls.

      Note

      Take care to prevent the balls from scattering.

    6. Coat the 4th driven gear synchronizer ring set with gear oil.

    7. A012F2ON01

      Using SST and a press, install the transmission clutch hub to the 4th driven gear.

      SST
      09309-14010

      Note

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

      Tech Tips

      Make sure that the protruding part on the 4th driven gear synchronizer ring set is fitted into the groove of the No. 2 transmission clutch hub.

  34. INSTALL SHAFT SNAP RING


    1. A012M1CC01
      *a Mark

      Select a new shaft 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.).

      Shaft Snap Ring Thickness:
      Mark Thickness mm (in.) Mark Thickness mm (in.)
      1 2.25 to 2.30 (0.0886 to 0.0906) 4 2.40 to 2.45 (0.0945 to 0.0965)
      2 2.30 to 2.35 (0.0906 to 0.0925) 5 2.45 to 2.50 (0.0965 to 0.0984)
      3 2.35 to 2.40 (0.0925 to 0.0945) 6 2.50 to 2.55 (0.0984 to 0.1004)
    2. A012LUQ

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

  35. INSPECT 4TH DRIVEN GEAR THRUST CLEARANCE

    Click here

  36. INSPECT 4TH DRIVEN GEAR RADIAL CLEARANCE

    Click here

  37. INSTALL 3RD DRIVEN GEAR


    1. A012GWNC03
      *a Inner Ring

      Coat the 3rd driven gear synchronizer ring set with gear oil.

    2. Install the inner ring to the 3rd driven gear.

    3. A012GLRC03
      *a Middle Ring

      Install the middle ring to the 3rd driven gear.

    4. A012ILSC03
      *a Outer Ring

      Install the outer ring to the 3rd driven gear.

    5. A012G2Z

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

    6. A012HTS

      Install the spacer to the No. 1 output shaft.

    7. A012HC3

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

  38. INSTALL OUTPUT SHAFT REAR BEARING


    1. A012NDVN01

      Using SST and a press, install the output shaft rear bearing to the No. 1 output shaft.

      SST
      09308-14010

      Note

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

      Tech Tips

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

  39. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A012HZFC01
      *a Mark

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

      Output Shaft Bearing Shaft Snap Ring Thickness:
      Mark Thickness mm (in.) Mark Thickness mm (in.)
      B 1.85 to 1.90 (0.0728 to 0.0748) 0 2.05 to 2.10 (0.0807 to 0.0827)
      C 1.90 to 1.95 (0.0748 to 0.0768) 1 2.10 to 2.15 (0.0827 to 0.0846)
      D 1.95 to 2.00 (0.0768 to 0.0787) 2 2.15 to 2.20 (0.0846 to 0.0866)
      E 2.00 to 2.05 (0.0787 to 0.0807) - -
    2. A012FJE

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

  40. INSPECT 3RD DRIVEN GEAR THRUST CLEARANCE

    Click here

  41. INSPECT 3RD DRIVEN GEAR RADIAL CLEARANCE

    Click here