OUTPUT SHAFT REASSEMBLY

PROCEDURE

  1. INSTALL FRONT OUTPUT SHAFT BEARING

    1. C200176E01

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

      09527-21011

      09608-06041

  2. INSTALL 1ST GEAR BUSH

    1. C200177

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

  3. INSTALL 1ST GEAR NEEDLE ROLLER BEARING

    1. C200178

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

  4. INSTALL 1ST GEAR

    1. C200179

      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. C200180C01

      *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. C200181

      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. C200182

      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. C200183

      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. C200184

      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. C200185

      Install the middle ring to the outer ring.

    4. C200186C01

      *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. C200187

      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. C200188

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

  12. INSTALL 2ND GEAR

    1. C200189C01

      *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. C200190E01

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

      09316-20011

      09950-40011

      09957-04010

      09950-60010

      09951-00180

      09951-00340

      09952-06010

  14. INSTALL OUTPUT GEAR SPACER

    1. C200191

      Install the output gear spacer to the output shaft.

  15. INSTALL 4TH DRIVEN GEAR

    1. C200192E01

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

      09316-60011

      09316-00011

  16. INSTALL 5TH DRIVEN GEAR

    1. C200193E01

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

      09316-60011

      09316-00011

  17. INSTALL OUTPUT GEAR SPACER

    1. C200194

      Install the output gear spacer to the output shaft.

  18. INSTALL 6TH DRIVEN GEAR

    1. C200195E01

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

      09316-60011

      09316-00011

  19. INSTALL REAR OUTPUT SHAFT BEARING

    1. C200196E01

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

      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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