OUTPUT SHAFT REASSEMBLY


  1. INSTALL FRONT OUTPUT SHAFT BEARING


    1. A01170WE01

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

      SST
      09309-14040
      09612-22011

  2. INSTALL 1ST GEAR BUSH


    1. A0118DQ

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

  3. INSTALL 1ST GEAR NEEDLE ROLLER BEARING


    1. A0118BL

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

  4. INSTALL 1ST GEAR


    1. A011A3HE01

      Coat the 1st gear with gear oil and install it onto 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. A0119X6

      Install the inner ring onto the 1st gear.

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

      Note

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

    4. Install the outer ring onto 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. A0118AU

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

      Note

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

  7. INSTALL NO. 1 SYNCHROMESH SHIFTING KEY


    1. A011AF7

      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. A0116ZZE01

      Install the reverse gear onto the No. 1 transmission clutch hub assembly.

      Note

      Install the reverse gear as shown in the illustration.

  9. INSTALL NO. 1 SYNCHRONIZER RING SET (FOR 2ND GEAR)


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

    2. A0117KX

      Install the outer ring onto 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. A011AYW

      Install the middle ring onto the outer ring.

    4. A01178UE02
      Text in Illustration
      *1 Cutout
      *2 Middle Ring
      *3 Outer Ring

      Install the inner ring onto the middle ring.

      Note

      Align the cutout of the outer ring with the protrusion of the inner ring before installing the inner ring.

  10. INSTALL INNER 2ND GEAR BEARING RACE


    1. A0119DGE01

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

  11. INSTALL 2ND GEAR NEEDLE ROLLER BEARING


    1. A011AZDE01

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

  12. INSTALL 2ND GEAR


    1. A0117LRE02
      Text in Illustration
      *1 Groove
      *2 Claw

      Coat the 2nd gear with gear oil and install it onto 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. A0117Y4E01

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

      SST
      09316-60011   ( 09316-00011 )

  14. INSTALL OUTPUT GEAR SPACER


    1. A011BTFE01

      Install the output gear spacer onto the output shaft.

  15. INSTALL 4TH DRIVEN GEAR


    1. A0117RPE01

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

      SST
      09309-37010
      09502-24010

  16. INSTALL 5TH DRIVEN GEAR


    1. A011AI7E01

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

      SST
      09316-60011   ( 09316-00011 )

  17. INSTALL OUTPUT GEAR SPACER


    1. A0118RXE01

      Install the output gear spacer onto the output shaft.

  18. INSTALL 6TH DRIVEN GEAR


    1. A011B50E01

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

      SST
      09226-10010

  19. INSTALL REAR OUTPUT SHAFT BEARING


    1. A0116YLE01

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

      SST
      09608-04031

  20. INSPECT 2ND GEAR RADIAL CLEARANCE


    1. A0118I9

      Using a dial indicator, measure the 2nd gear radial clearance.

      Standard clearance
      0.009 to 0.077 mm (0.000354 to 0.00303 in.)
      Maximum clearance
      0.077 mm (0.00303 in.)

      If the clearance exceeds the maximum, replace the 2nd gear, 2nd gear needle roller bearing or output shaft.

  21. INSPECT 1ST GEAR RADIAL CLEARANCE


    1. A0119JE

      Using a dial indicator, measure the 1st gear radial clearance.

      Standard clearance
      0.009 to 0.077 mm (0.000354 to 0.00303 in.)
      Maximum clearance
      0.077 mm (0.00303 in.)

      If the clearance exceeds the maximum, replace the 1st gear, 1st gear needle roller bearing or output shaft.

  22. INSPECT 2ND GEAR THRUST CLEARANCE


    1. A0118CR

      Using a dial indicator, measure the 2nd gear thrust clearance.

      Standard clearance
      0.15 to 0.33 mm (0.00591 to 0.0130 in.)
      Maximum clearance
      0.33 mm (0.0130 in.)

      If the clearance exceeds the maximum, replace the inner 2nd gear bearing race, No. 1 transmission clutch hub, 2nd gear or 3rd driven gear.

  23. INSPECT 1ST GEAR THRUST CLEARANCE


    1. A011B0E

      Using a dial indicator, measure the 1st gear thrust clearance.

      Standard clearance
      0.20 to 0.38 mm (0.00787 to 0.0150 in.)
      Maximum clearance
      0.38 mm (0.0150 in.)

      If the clearance exceeds the maximum, replace the No. 1 transmission clutch hub, 1st gear bush or 1st gear.