OUTPUT SHAFT REASSEMBLY

PROCEDURE


  1. INSTALL NEEDLE ROLLER BEARING


    1. A01GC3G

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

  2. INSTALL REVERSE DRIVEN GEAR


    1. A01GC4F

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

  3. INSTALL NO. 4 TRANSMISSION CLUTCH HUB


    1. A01GC75C02
      *1 No. 4 Transmission Clutch Hub
      *2 Key Spring
      *3 Shifting Key
      *4 Reverse Driven Gear Synchronizer Ring
      *5 No. 4 Transmission Hub Sleeve
      *a Claw

      Install the key spring and 2 shifting keys to the No. 4 transmission clutch hub.

      Tech Tips


      • Install the shifting key with the grooves on the clutch hub side.

      • Install the key spring with the claw on the clutch hub side.

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

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

    3. A01GCVVE01

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

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

  4. INSTALL SHAFT SNAP RING


    1. A01GA7EC01
      *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.).

      Standard shaft snap ring thickness
      Mark Thickness Mark Thickness
      A 2.25 mm (0.0886 in.) E 2.45 mm (0.0965 in.)
      B 2.30 mm (0.0906 in.) F 2.50 mm (0.0984 in.)
      C 2.35 mm (0.0925 in.) G 2.55 mm (0.100 in.)
      D 2.40 mm (0.0945 in.) H 2.60 mm (0.102 in.)
    2. A01GBTG

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

  5. INSPECT REVERSE DRIVEN GEAR THRUST CLEARANCE

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  6. INSPECT REVERSE DRIVEN GEAR RADIAL CLEARANCE

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  7. INSTALL 5TH DRIVEN GEAR


    1. A01GAY5

      Install the 5th gear bearing spacer into the No. 2 output shaft.

    2. A01GBP9

      Coat the 2 pieces of the 5th gear needle roller bearing with gear oil, and install them into the No. 2 output shaft.

    3. A01GC7X

      Install the output shaft collar into the No. 2 output shaft.

    4. A01GBLQ

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

  8. INSTALL NO. 3 TRANSMISSION CLUTCH HUB


    1. A01GBJP

      Apply of gear oil to the sleeve and hub.

    2. Install the hub sleeve to the clutch hub.

    3. Install the 3 shifting keys to the clutch hub.

    4. Install the 3 shifting key springs to the clutch hub.

    5. Place the 3 balls in the holes of the shifting keys, and install the hub sleeve while pushing in the balls.

      Note

      Take care to prevent the balls from scattering.

    6. A01GBASE01

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

    7. Using SST and a press, press in 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 synchronizer ring is fitted into the groove of the clutch hub.

  9. INSTALL SHAFT SNAP RING


    1. A01GASKC01
      *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.).

      Standard shaft snap ring thickness
      Mark Thickness Mark Thickness
      1 2.25 mm (0.0886 in.) 4 2.40 mm (0.0945 in.)
      2 2.30 mm (0.0906 in.) 5 2.45 mm (0.0965 in.)
      3 2.35 mm (0.0925 in.) 6 2.50 mm (0.0984 in.)
    2. A01GC3W

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

  10. INSPECT 5TH DRIVEN GEAR THRUST CLEARANCE

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  11. INSPECT 5TH DRIVEN GEAR RADIAL CLEARANCE

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  12. INSTALL 6TH DRIVEN GEAR


    1. A01GAOV

      Install the spacer into the No. 2 output shaft.

    2. A01GBRZ

      Coat the 2 pieces of the needle roller bearing with gear oil, and install them into the No. 2 output shaft.

    3. A01GBZI

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

    4. A01GCLA

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

  13. INSTALL REAR NO. 2 OUTPUT SHAFT BEARING


    1. A01GCWWE01

      Using SST and press, press in the rear No. 2 output shaft 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. A01GB10C01
      *a Mark

      Select a new No. 2 output shaft bearing snap ring, using the table below, that makes the thrust clearance of the 6th driven gear less than 0.1 mm (0.00394 in.).

      Standard No. 2 output shaft bearing snap ring thickness
      Mark Thickness Mark Thickness
      B 1.85 mm (0.0728 in.) 0 2.05 mm (0.0807 in.)
      C 1.90 mm (0.0748 in.) 1 2.10 mm (0.0827 in.)
      D 1.95 mm (0.0768 in.) 2 2.15 mm (0.0846 in.)
      E 2.00 mm (0.0787 in.) - -
    2. A01GB4U

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

  15. INSPECT 6TH DRIVEN GEAR THRUST CLEARANCE

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  16. INSPECT 6TH DRIVEN GEAR RADIAL CLEARANCE

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  17. INSTALL FRONT NO. 2 OUTPUT SHAFT BEARING


    1. A01GBANE01

      Using SST and a press, press in the front No. 2 output shaft bearing into the No. 2 output shaft.

      SST
      09309-37010
      09506-30012

  18. INSTALL FRONT OUTPUT SHAFT BEARING


    1. A01GBG6E01

      Using SST and press, press in the front output shaft bearing into the No. 1 output shaft.

      SST
      09309-14040

  19. INSTALL FRONT OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A01GA2D

      Using a snap ring expander, install a new front output shaft bearing shaft snap ring into the No. 1 output shaft.

  20. INSTALL 1ST DRIVEN GEAR


    1. A01GBNI

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

    2. A01GCFH

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

  21. INSTALL NO. 1 TRANSMISSION CLUTCH HUB


    1. A01GA68

      Apply of gear oil to the sleeve and hub.

    2. Install the hub sleeve to the clutch hub.

    3. Install the 3 shifting keys to the clutch hub.

    4. Install the 3 shifting key springs to the clutch hub.

    5. Place the 3 balls in the holes of the shifting keys, and install the hub sleeve while pushing in the balls.

      Note

      Take care to prevent the balls from scattering.

    6. A01GAHWE01

      Coat the 3 pieces of the 1st driven gear synchronizer ring set with gear oil, and install them to the 1st driven gear.

    7. Using SST and a press, press in 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 synchronizer ring is fitted into the groove of the clutch hub.

  22. INSTALL 2ND DRIVEN GEAR SYNCHRONIZER RING SET


    1. A01GAS9

      Coat the 3 pieces of the 2nd driven gear synchronizer ring set with gear oil, and install them to the No. 1 output shaft.

  23. INSTALL SYNCHROMESH SHIFTING KEY BALL

    A01GDGC

    1. Using a magnet hand, install the synchromesh shifting key ball onto the No. 1 output shaft.

  24. INSTALL NEEDLE ROLLER BEARING


    1. A01GBYP

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

  25. INSTALL 2ND DRIVEN GEAR


    1. A01GA3W

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

  26. INSTALL INNER 2ND DRIVEN GEAR BEARING RACE


    1. A01GCQC

      Align the groove of the inner 2nd driven gear bearing race with the synchromesh shifting key ball, and install it.

  27. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A01GCWQ

      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. INSTALL 4TH DRIVEN GEAR


    1. A01GBE8

      Install the spacer into the No. 1 output shaft.

    2. A01GCIL

      Coat the 2 pieces of the needle roller bearing with gear oil, and install them into the No. 1 output shaft.

    3. A01GC0V

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

  29. INSTALL NO. 2 TRANSMISSION CLUTCH HUB


    1. A01GCD7

      Apply of gear oil to the sleeve and hub.

    2. Install the hub sleeve to the clutch hub.

    3. Install the 3 shifting keys to the clutch hub.

    4. Install the 3 shifting key springs to the clutch hub.

    5. Place the 3 balls in the holes of the shifting keys, and install the hub sleeve while pushing in the balls.

      Note

      Take care to prevent the balls from scattering.

    6. Coat the 3 pieces of the 4th driven gear synchronizer ring set with gear oil, and install them into the 4th driven gear.

    7. A01GCCOE01

      Using SST and a press, press in the No. 2 transmission hub sleeve to the No. 1 output shaft.

      SST
      09309-14010

      Tech Tips

      Make sure that the protruding part on the synchronizer ring is fitted into the groove of the clutch hub.

      Note

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

  30. INSTALL SHAFT SNAP RING


    1. A01GCR1C01
      *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.).

      Standard shaft snap ring thickness
      Mark Thickness Mark Thickness
      1 2.25 mm (0.0886 in.) 4 2.40 mm (0.0945 in.)
      2 2.30 mm (0.0906 in.) 5 2.45 mm (0.0965 in.)
      3 2.35 mm (0.0925 in.) 6 2.50 mm (0.0984 in.)
    2. A01GAEK

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

  31. INSPECT 1ST DRIVEN GEAR THRUST CLEARANCE

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  32. INSPECT 1ST DRIVEN GEAR RADIAL CLEARANCE

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  33. INSPECT 2ND DRIVEN GEAR THRUST CLEARANCE

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  34. INSPECT 2ND DRIVEN GEAR RADIAL CLEARANCE

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  35. INSPECT 4TH DRIVEN GEAR THRUST CLEARANCE

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  36. INSPECT 4TH DRIVEN GEAR RADIAL CLEARANCE

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  37. INSTALL 3RD DRIVEN GEAR


    1. A01G9YX

      Coat the 3rd driven gear synchronizer ring set with gear oil, and install it into the No. 1 output shaft.

    2. A01GBOB

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

    3. A01GDGF

      Install the spacer into the No. 1 output shaft.

    4. A01GCHR

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

  38. INSTALL FRONT OUTPUT SHAFT BEARING


    1. A01GBPGE02

      Using SST and press, press in the output shaft front bearing into the No. 1 output shaft.

      SST
      09308-14010

      Tech Tips

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

      Note

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

  39. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A01GDHCC01
      *a Mark

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

      Standard output shaft bearing snap ring thickness
      Mark Thickness Mark Thickness
      B 1.85 mm (0.0728 in.) 0 2.05 mm (0.0807 in.)
      C 1.90 mm (0.0748 in.) 1 2.10 mm (0.0827 in.)
      D 1.95 mm (0.0768 in.) 2 2.15 mm (0.0846 in.)
      E 2.00 mm (0.0787 in.) - -
    2. A01GBNW

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

  40. INSPECT 3RD DRIVEN GEAR THRUST CLEARANCE

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  41. INSPECT 3RD DRIVEN GEAR RADIAL CLEARANCE

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