OUTPUT SHAFT INSTALLATION


  1. INSTALL NO. 2 TRANSMISSION CLUTCH HUB

    A01DX1UE01

    1. Coat the hub sleeve with gear oil, and install it to the clutch hub.

      Note

      Be sure to set the hub sleeve to the clutch hub in the correct direction.

    2. A01E0GVE01

      Install the 3 synchromesh shifting keys to the clutch hub with the 2 synchromesh shifting key springs.

      Tech Tips

      Do not set both openings of the shifting key springs in the same position.

  2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING

    A01DVVSE01

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

  3. INSTALL 3RD GEAR

    A01DZ05E01

    1. Coat the 3rd gear with gear oil, and install it to the output shaft.

  4. INSTALL NO. 2 SYNCHRONIZER RING

    A01DYYBE01

    1. Coat the synchronizer ring with gear oil, and install it to the 3rd gear.

  5. INSTALL NO. 2 TRANSMISSION CLUTCH HUB

    A01DYPSE01

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

      SST
      09316-60011   ( 09316-00021 )
    2. A01E1JRE01

      Select a clutch hub shaft snap ring that will allow minimal axial play.

      Standard clearance
      0.10 mm (0.039 in.) or less
      Standard clutch hub shaft snap ring thickness
      Mark Thickness
      C-1 1.75 to 1.80 mm (0.0689 to 0.0709 in.)
      D 1.80 to 1.85 mm (0.0709 to 0.0728 in.)
      D-1 1.85 to 1.90 mm (0.0728 to 0.0748 in.)
      E 1.90 to 1.95 mm (0.0748 to 0.0768 in.)
      E-1 1.95 to 2.00 mm (0.0768 to 0.0787 in.)
      F 2.00 to 2.05 mm (0.0787 to 0.0807 in.)
      F-1 2.05 to 2.10 mm (0.0807 to 0.0827 in.)
    3. A01DY60E01

      Using a snap ring expander, install the snap ring.

  6. INSPECT 3RD GEAR THRUST CLEARANCE

    A01DWWGE01

    1. Using a feeler gauge, measure the thrust clearance.

      Standard clearance
      0.10 to 0.25 mm (0.0039 to 0.0098in.)

  7. INSTALL NO. 1 TRANSMISSION CLUTCH HUB

    A01E0S5E01

    1. Coat the reverse gear with gear oil, and install it to the clutch hub.

      Note

      Be sure to set the reverse gear to the clutch hub in the correct direction.

    2. A01E0GVE01

      Install 3 synchromesh shifting keys to the clutch hub with the 2 synchromesh shifting key springs.

      Tech Tips

      Do not set both openings of the shifting key springs in the same position.

  8. INSTALL 2ND GEAR NEEDLE ROLLER BEARING

    A01E2CLE01

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

  9. INSTALL 2ND GEAR

    A01E1EQE01

    1. Coat the 2nd gear with gear oil, and install it to the output shaft.

  10. INSTALL NO. 1 SYNCHRONIZER RING (for 2nd Gear)

    A01E21XE01

    1. Coat the No. 1 synchronizer ring with gear oil, and install it to the 2nd gear.

  11. INSTALL NO. 1 TRANSMISSION CLUTCH HUB

    A01DWZAE01

    1. Using SST and a press, press in the clutch hub to the output shaft.

      SST
      09316-60011

  12. INSPECT 2ND GEAR THRUST CLEARANCE

    A01E22PE02

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

      Standard clearance
      0.10 to 0.250 mm (0.0039 to 0.0098 in.)

  13. INSTALL NO. 1 SYNCHRONIZER RING (for 1st Gear)

    A01DYFEE01

    1. Coat the synchronizer ring with gear oil, and install it to the No. 1 clutch hub.

  14. INSTALL 1ST GEAR BEARING INNER RACE LOCK BALL

    A01DWZXE01

    1. Coat the lock ball with gear oil, and install it to the output shaft.

  15. INSTALL 1ST GEAR BEARING INNER RACE

    A01DZTZE01

    1. Coat the needle roller bearing with gear oil.

    2. Install the inner race and the needle roller bearing to the 1st gear.

  16. INSTALL 1ST GEAR

    A01DVH1E01

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

  17. INSTALL OUTPUT SHAFT CENTER BEARING

    A01E1HXE01

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

      SST
      09316-60011   ( 09316-00021 )

  18. INSPECT 1ST GEAR THRUST CLEARANCE

    A01DXXIE02

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

      Standard clearance
      0.10 to 0.25 mm (0.0039 to 0.0078 in.)

  19. INSTALL 5TH GEAR

    A01DYN7E01

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

      SST
      09316-60011   ( 09316-00021 )
    2. A01DYUDE01

      Select a snap ring that will allow minimal axial play.

      Standard clearance
      0.10 mm (0.039 in.) or less
      Standard output shaft bearing shaft snap ring
      Mark Thickness
      A 2.67 to 2.72 mm (0.1051 to 0.1071 in.)
      B 2.73 to 2.78 mm (0.1075 to 0.1094 in.)
      C 2.79 to 2.84 mm (0.1098 to 0.1118 in.)
      D 2.85 to 2.90 mm (0.1122 to 0.1141 in.)
      E 2.91 to 2.96 mm (0.1146 to 0.1165 in.)
      F 2.97 to 3.02 mm (0.1169 to 0.1189 in.)
      G 3.03 to 3.08 mm (0.1193 to 0.1213 in.)
      H 3.09 to 3.14 mm (0.1217 to 0.1236 in.)
      J 3.15 to 3.20 mm (0.1240 to 0.1260 in.)
      K 3.21 to 3.26 mm (0.1264 to 0.1283 in.)
      L 3.27 to 3.32 mm (0.1287 to 0.1307 in.)
    3. A01DY4WE01

      Using a screwdriver and hammer, tap in the snap ring.

  20. INSTALL SPEEDOMETER DRIVE GEAR

    A01DXLHE01

    1. Using a snap ring expander, install the snap ring.

    2. Install the ball.

    3. Install the drive gear.

    4. Using a snap ring expander, install the snap ring.

  21. INSPECT 3RD GEAR RADIAL CLEARANCE

    A01E2CRE01

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

      Standard clearance
      0.008 to 0.034 mm (0.0003 to 0.0013 in.)

      • If the clearance is not as specified, replace the needle roller bearing.

  22. INSPECT 2ND GEAR RADIAL CLEARANCE

    A01DVJ1E01

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

      Standard clearance
      0.008 to 0.034 mm (0.0003 to 0.0013 in.)

      • If the clearance is not as specified, replace the needle roller bearing.

  23. INSPECT 1ST GEAR RADIAL CLEARANCE

    A01DVZ6E01

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

      Standard clearance
      0.009 to 0.056 mm (0.0004 to 0.0022 in.)

      • If the clearance is not as specified, replace the needle roller bearing.