OUTPUT SHAFT REASSEMBLY


  1. INSTALL FRONT OUTPUT SHAFT BEARING


    1. A00DRUXE01

      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. A00DQO7

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

  3. INSTALL 1ST GEAR NEEDLE ROLLER BEARING


    1. A00DQYQ

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

  4. INSTALL 1ST GEAR


    1. A00DQXT

      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. A00DPZG

      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. A00DV31

      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. A00DQXR

      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. A00DPWX

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

    2. A00DTHW

      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. A00DR6I

      Install the middle ring to the outer ring.

    4. A00DQUOE01
      Text in Illustration
      *1 Cutout
      *2 Inner Ring
      *3 Outer Ring

      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. A00DRD5

      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. A00DQVC

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

  12. INSTALL 2ND GEAR


    1. A00DRD8E01
      Text in Illustration
      *1 Groove
      *2 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. A00DTF2E01

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

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

  14. INSTALL OUTPUT GEAR SPACER


    1. A00DQCD

      Install the output gear spacer to the output shaft.

  15. INSTALL 4TH DRIVEN GEAR


    1. A00DSRDE01

      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. A00DV2DE01

      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. A00DS15

      Install the output gear spacer to the output shaft.

  18. INSTALL 6TH DRIVEN GEAR


    1. A00DQMDE01

      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. A00DSVXE01

      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


    1. A005U02

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

      Standard clearance
      0.009 to 0.047 mm (0.000354 to 0.00185 in.)
      Maximum clearance
      0.047 mm (0.00185 in.)

      If the clearance is more than the maximum, replace the 2nd gear, 2nd gear needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  21. INSPECT 1ST GEAR RADIAL CLEARANCE


    1. A005VQX

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

      Standard clearance
      0.009 to 0.047 mm (0.000354 to 0.00185 in.)
      Maximum clearance
      0.047 mm (0.00185 in.)

      If the clearance is more than the maximum, replace the 1st gear, 1st gear needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  22. INSPECT 2ND GEAR THRUST CLEARANCE


    1. A005UQJ

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

      Standard clearance
      0.16 to 0.33 mm (0.00629 to 0.0130 in.)
      Maximum clearance
      0.33 mm (0.0130 in.)

      If the clearance is more than the maximum, replace the inner 2nd gear bearing race, No. 1 transmission clutch hub, 2nd gear or 3rd driven gear. Replace the part or parts determined to be the most likely cause of the problem.

  23. INSPECT 1ST GEAR THRUST CLEARANCE


    1. A005TYC

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

      Standard clearance
      0.23 to 0.37 mm (0.00905 to 0.0146 in.)
      Maximum clearance
      0.37 mm (0.0146 in.)

      If the clearance is more than the maximum, replace the No. 1 transmission clutch hub, 1st gear bush or 1st gear. Replace the part or parts determined to be the most likely cause of the problem.