OUTPUT SHAFT REASSEMBLY

PROCEDURE


  1. INSTALL NO. 2 TRANSMISSION HUB SLEEVE


    1. A01L9D1

      Install the 3 No. 2 synchromesh shifting key springs and 3 No. 2 synchromesh shifting keys to the No. 2 transmission clutch hub.

      Note

      Be careful of the direction of the No. 2 transmission hub sleeve and that of the No. 2 transmission clutch hub.

      A01L8WAC01
      B0068HS Front Side

    2. Apply gear oil to the sliding part of the No. 2 transmission hub sleeve, and install it to the No. 2 transmission clutch hub.

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING


    1. A01LBUO

      Apply gear oil to the 3rd gear needle roller bearing, and install it to the output shaft.

  3. INSTALL 3RD GEAR


    1. A01LAST

      Apply gear oil to the 3rd gear, and install it to the output shaft.

  4. INSTALL NO. 2 SYNCHRONIZER RING SET (FOR 3RD GEAR)


    1. A01L8CP

      Apply gear oil to the No. 2 synchronizer ring set (for 3rd gear), and install it to the 3rd gear.

  5. INSTALL NO. 2 TRANSMISSION CLUTCH HUB


    1. A01LCN9N01

      Using SST and a press, press in the No. 2 transmission clutch hub to the output shaft.

      SST
      09608-06041

      Note


      • Install the hub while aligning the cutout of the transmission clutch hub and the protrusion of the synchronizer ring.

      • The 3rd gear should be able to rotate smoothly.

    2. Select a snap ring so that the clearance between the No. 2 transmission clutch hub and clutch hub set shaft snap ring is within the specification.

      Note

      Do not damage the sliding surface of the bearing.

      Standard clearance
      0.10 mm (0.00393 in.) or less
      Snap Ring Thickness
      Thickness
      1.80 to 1.85 mm (0.0709 to 0.0728 in.)
      1.85 to 1.90 mm (0.0729 to 0.0748 in.)
      1.90 to 1.95 mm (0.0748 to 0.0767 in.)
      1.95 to 2.00 mm (0.0768 to 0.0787 in.)
      2.00 to 2.05 mm (0.0787 to 0.0807 in.)
      2.05 to 2.10 mm (0.0808 to 0.0826 in.)
      2.10 to 2.15 mm (0.0827 to 0.0846 in.)
    3. A01LDY5

      Using a snap ring expander, install the clutch hub set shaft snap ring.

  6. INSTALL 2ND GEAR NEEDLE ROLLER BEARING


    1. A01L8B5

      Apply gear oil to the 2nd gear needle roller bearing, and install it to the output shaft.

  7. INSTALL 2ND GEAR


    1. A01LD1D

      Apply gear oil to the 2nd gear, and install it to the output shaft.

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


    1. A01LARO

      Apply gear oil to the No. 1 synchronizer ring set (for 2nd gear), and install it to the 2nd gear.

  9. INSTALL REVERSE GEAR


    1. A01LBUP

      Using a screwdriver, install the 3 No. 1 synchromesh shifting key springs and 3 No. 1 synchromesh shifting keys to the No. 1 transmission clutch hub.

    2. Apply gear oil to the reverse gear, and install it to the No. 1 transmission clutch hub.

      Note

      Be careful of the direction of the reverse gear and that of the No. 1 transmission clutch hub.

      A01LENQC01
      B0068HS Front Side

  10. INSTALL NO. 1 TRANSMISSION CLUTCH HUB


    1. A01LG2WN01

      Using SST and a press, press in the No. 1 transmission clutch hub to the output shaft.

      SST
      09316-60011   ( 09316-00041 )

      Note


      • Install the No. 1 clutch hub while aligning the cutout of the No. 1 clutch hub and the protrusion of synchronizer ring.

      • The 1st gear should rotate freely.

    2. Select a bearing shaft snap ring so that the thrust clearance between the No. 1 transmission clutch hub and bearing shaft snap ring is within the specification.

      Standard clearance
      0.1 mm (0.0393 in.) or less

      Note

      Do not damage the sliding surface of the bearing.

      Snap Ring Thickness
      Thickness
      2.30 to 2.35 mm (0.0906 to 0.0925 in.)
      2.35 to 2.40 mm (0.0926 to 0.0944 in.)
      2.40 to 2.45 mm (0.0945 to 0.0964 in.)
      2.45 to 2.50 mm (0.0965 to 0.0984 in.)
      2.50 to 2.55 mm (0.0985 to 0.100 in.)
      2.55 to 2.60 mm (0.101 to 0.102 in.)
      2.60 to 2.65 mm (0.103 to 0.104 in.)
    3. A01L9UG

      Using a brass bar and hammer, install the bearing shaft snap ring.

  11. INSTALL 1ST GEAR BEARING SPACER


    1. A01LEJP

      Apply gear oil to the 1st gear bearing spacer, and install it to the output shaft.

  12. INSTALL 1ST GEAR NEEDLE ROLLER BEARING


    1. A01LEAS

      Apply gear oil to the 1st gear needle roller bearing, and install it to the output shaft.

  13. INSTALL 1ST GEAR THRUST WASHER PIN


    1. A01LD0U

      Install the 1st gear thrust washer pin to the output shaft.

  14. INSTALL NO. 1 SYNCHRONIZER RING SET (FOR 1ST GEAR)


    1. A01LBQH

      Apply gear oil to the No. 1 synchronizer ring set (for 1st gear), and install it to the output shaft.

  15. INSTALL 1ST GEAR


    1. A01LCPL

      Apply gear oil to the 1st gear, and install it to the output shaft.

  16. INSTALL 1ST GEAR THRUST WASHER


    1. A01LCPJ

      Apply gear oil to the 1st gear thrust washer, and install it to the output shaft.

  17. INSTALL OUTPUT SHAFT CENTER BEARING


    1. A01LBAZN01

      Using SST and a press, press in a new output shaft center bearing to the output shaft.

      SST
      09316-60011   ( 09316-00031 )

      Note

      Install the output shaft center bearing so that the snap ring groove of the bearing is located at the rear.

  18. INSTALL 5TH GEAR


    1. A01LCH8N01

      Using SST and a press, press in the 5th gear to the output shaft.

      SST
      09316-60011   ( 09316-00031 )

      Note


      • Check that the splines of the 5th gear and output shaft properly match before pressing.

      • Install the 5th gear so that the convex part of the gear faces forward.

  19. INSPECT 1ST GEAR THRUST CLEARANCE

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  20. INSPECT 2ND GEAR THRUST CLEARANCE

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  21. INSPECT 3RD GEAR THRUST CLEARANCE

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  22. INSPECT 1ST GEAR RADIAL CLEARANCE

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  23. INSPECT 2ND GEAR RADIAL CLEARANCE

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  24. INSPECT 3RD GEAR RADIAL CLEARANCE

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