OUTPUT SHAFT REASSEMBLY

PROCEDURE

  1. INSTALL FRONT OUTPUT SHAFT BEARING

    1. C194384E10

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

      09309-14040

      09612-22011

  2. INSTALL 1ST GEAR BUSH

    1. C194368

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

  3. INSTALL 1ST GEAR NEEDLE ROLLER BEARING

    1. C194367

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

  4. INSTALL 1ST GEAR

    1. C363644

      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. C194386

      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. C194387

      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. C194363

      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. C363645

      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. C363646

      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. C194390

      Install the middle ring to the outer ring.

    4. C194391E08

      Install the inner ring to the middle ring.

      Table 1. Text in Illustration

      *1

      Cutout

      *2

      Middle Ring

      *3

      Outer 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. C363638

      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. C363637

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

  12. INSTALL 2ND GEAR

    1. C194392E09

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

      Table 2. Text in Illustration

      *1

      Groove

      *2

      Claw
      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. C194393E08

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

      09316-60011

      09316-00011

  14. INSTALL OUTPUT GEAR SPACER

    1. C363636

      Install the output gear spacer to the output shaft.

  15. INSTALL 4TH DRIVEN GEAR

    1. C194394E08

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

      09309-37010

      09502-24010

  16. INSTALL 5TH DRIVEN GEAR

    1. C194395E06

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

      09316-60011

      09316-00011

  17. INSTALL OUTPUT GEAR SPACER

    1. C363635

      Install the output gear spacer to the output shaft.

  18. INSTALL 6TH DRIVEN GEAR

    1. C194396E07

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

      09226-10010

  19. INSTALL REAR OUTPUT SHAFT BEARING

    1. C194397E01

      Using SST and a press, install a new rear output shaft bearing to 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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