OUTPUT SHAFT REASSEMBLY

PROCEDURE


  1. INSTALL FRONT OUTPUT SHAFT BEARING


    1. A00YVG8E01

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

      SST
      09527-21011
      09608-06041

  2. INSTALL 1ST GEAR BUSH


    1. A00YTRV

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

  3. INSTALL 1ST GEAR NEEDLE ROLLER BEARING


    1. A00YXCE

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

  4. INSTALL 1ST GEAR


    1. A00YSOJ

      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. A00YSNXC01
      *1 Outer Ring
      *2 Middle Ring
      *3 Inner Ring

      Install the inner ring to the 1st gear.

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

      Note

      Attach 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. A00YSES

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

      Note

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

  7. INSTALL NO. 1 SYNCHROMESH SHIFTING KEY


    1. A00YRI2

      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. A00YT5B

      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 2nd gear cone and No. 1 synchronizer ring set (inner ring, middle ring and outer ring) with gear oil.

    2. A00YRVF

      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. A00YTW3

      Install the middle ring to the outer ring.

    4. A00YX34C01
      *1 Inner Ring
      *2 Outer Ring
      *a 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. A00YRMI

      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. A00YRL9

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

  12. INSTALL 2ND GEAR


    1. A00YR0QC01
      *a Groove
      *b Claw

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

      Note

      Align the claw of the middle ring with the groove of the 2nd gear before installing the 2nd gear.

  13. INSTALL 3RD DRIVEN GEAR


    1. A00YTHNE01

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

      SST
      09316-20011
      09950-40011   ( 09957-04010 )
      09950-60010   ( 09951-00180, 09951-00340, 09952-06010 )

  14. INSTALL OUTPUT GEAR SPACER


    1. A00YWGM

      Install the output gear spacer to the output shaft.

  15. INSTALL 4TH DRIVEN GEAR


    1. A00YRITE01

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

      SST
      09316-60011   ( 09316-00011 )

  16. INSTALL 5TH DRIVEN GEAR


    1. A00YXSCE01

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

      SST
      09316-60011   ( 09316-00011 )

  17. INSTALL OUTPUT GEAR SPACER


    1. A00YS63

      Install the output gear spacer to the output shaft.

  18. INSTALL 6TH DRIVEN GEAR


    1. A00YT6ZE01

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

      SST
      09316-60011   ( 09316-00011 )

  19. INSTALL REAR OUTPUT SHAFT BEARING


    1. A00YTTEE01

      Using SST and a press, press a new rear output shaft bearing onto 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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