OUTPUT SHAFT REASSEMBLY

PROCEDURE


  1. INSTALL FRONT OUTPUT SHAFT BEARING


    1. A005LYKE07

      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. A005JP1

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

  3. INSTALL 1ST GEAR NEEDLE ROLLER BEARING


    1. A005I07

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

  4. INSTALL 1ST GEAR


    1. A005GDGE01

      Coat the 1st gear with manual transaxle 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 manual transaxle oil.

    2. A005LYPE02
      Text in Illustration
      *1 Inner Ring
      *2 Middle Ring
      *3 Outer Ring

      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. A005GYR

      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. A005JVK

      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 manual transaxle oil.

    2. A005LEWE01

      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 manual transaxle oil.

    2. A005IEB

      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. A005MI2

      Install the middle ring onto the outer ring.

    4. A005I4JE06
      Text in Illustration
      *1 Inner Ring
      *2 Outer Ring
      *a Cutout

      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. A005L39E01

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

  11. INSTALL 2ND GEAR NEEDLE ROLLER BEARING


    1. A005IA8E01

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

  12. INSTALL 2ND GEAR


    1. A005JF3E06
      Text in Illustration
      *a Groove
      *b Claw

      Coat the 2nd gear with manual transaxle 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. A005GOJE05

      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. A005K17E01

      Install the output gear spacer onto the output shaft.

  15. INSTALL 4TH DRIVEN GEAR


    1. A005GE7E05

      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. A005IBTE01

      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. A005IOEE01

      Install the output gear spacer onto the output shaft.

  18. INSTALL 6TH DRIVEN GEAR


    1. A005JRME04

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

      SST
      09226-10010
  19. INSTALL REAR OUTPUT SHAFT BEARING


    1. A005MILE01

      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

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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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