OUTPUT SHAFT REASSEMBLY

PROCEDURE

1. INSTALL NEEDLE ROLLER BEARING

   1. 

      Coat the needle roller bearing with gear oil, and install it into the No. 2 output shaft.

2. INSTALL REVERSE DRIVEN GEAR

   1. 

      Coat the reverse driven gear with gear oil, and install it into the No. 2 output shaft.

3. INSTALL NO. 4 TRANSMISSION CLUTCH HUB

   1. 

      *1	No. 4 Transmission Clutch Hub
      *2	Key Spring
      *3	Shifting Key
      *4	Reverse Driven Gear Synchronizer Ring
      *5	No. 4 Transmission Hub Sleeve
      *a	Claw

      Install the key spring and 2 shifting keys to the No. 4 transmission clutch hub.

      Tip:

      • Install the shifting key with the grooves on the clutch hub side.

      • Install the key spring with the claw on the clutch hub side.

      • Refer to the illustration when installing the key spring and shifting keys.

   2. Install the No. 4 transmission hub sleeve to the reverse driven gear as shown in the illustration.

   3. 

      Coat the No. 4 transmission clutch hub with gear oil, and install it into the No. 2 output shaft.

   4. Using SST and a press, press in the reverse driven gear and No. 4 transmission clutch hub into the No. 2 output shaft.

      09308-14010

      Note:

      After installation, make sure that the gear and synchronizer ring move smoothly.

      Tip:

      Make sure that the protruding part on the synchronizer ring is fitted into the groove of the clutch hub.

4. INSTALL SHAFT SNAP RING

   1. 

      *a

      Mark

      Select a new shaft snap ring, using the table below, that makes the thrust clearance of the No. 4 transmission clutch hub less than 0.1 mm (0.00394 in.).

      Standard shaft snap ring thickness

      Mark	Thickness	Mark	Thickness
      A	2.25 mm (0.0886 in.)	E	2.45 mm (0.0965 in.)
      B	2.30 mm (0.0906 in.)	F	2.50 mm (0.0984 in.)
      C	2.35 mm (0.0925 in.)	G	2.55 mm (0.100 in.)
      D	2.40 mm (0.0945 in.)	H	2.60 mm (0.102 in.)

   2. 

      Using a brass bar and hammer, tap the shaft snap ring onto the No. 2 output shaft.

5. INSPECT REVERSE DRIVEN GEAR THRUST CLEARANCE

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6. INSPECT REVERSE DRIVEN GEAR RADIAL CLEARANCE

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7. INSTALL 5TH DRIVEN GEAR

   1. 

      Install the 5th gear bearing spacer into the No. 2 output shaft.

   2. 

      Coat the 2 pieces of the 5th gear needle roller bearing with gear oil, and install them into the No. 2 output shaft.

   3. 

      Install the output shaft collar into the No. 2 output shaft.

   4. 

      Coat the 5th driven gear with gear oil, and install it into the No. 2 output shaft.

8. INSTALL NO. 3 TRANSMISSION CLUTCH HUB

   1. 

      Apply of gear oil to the sleeve and hub.

   2. Install the hub sleeve to the clutch hub.

   3. Install the 3 shifting keys to the clutch hub.

   4. Install the 3 shifting key springs to the clutch hub.

   5. Place the 3 balls in the holes of the shifting keys, and install the hub sleeve while pushing in the balls.

      Note:

      Take care to prevent the balls from scattering.

   6. 

      Coat the 5th driven gear synchronizer ring with gear oil, and install it to the 5th driven gear.

   7. Using SST and a press, press in the No. 3 transmission clutch hub to the No. 2 output shaft.

      09308-14010

      Note:

      After installation, make sure that the gear and synchronizer ring move smoothly.

      Tip:

      Make sure that the protruding part on the synchronizer ring is fitted into the groove of the clutch hub.

9. INSTALL SHAFT SNAP RING

   1. 

      *a

      Mark

      Select a new shaft snap ring, using the table below, that makes the thrust clearance of the No. 3 transmission clutch hub less than 0.1 mm (0.00394 in.).

      Standard shaft snap ring thickness

      Mark	Thickness	Mark	Thickness
      1	2.25 mm (0.0886 in.)	4	2.40 mm (0.0945 in.)
      2	2.30 mm (0.0906 in.)	5	2.45 mm (0.0965 in.)
      3	2.35 mm (0.0925 in.)	6	2.50 mm (0.0984 in.)

   2. 

      Using a brass bar and hammer, tap the snap ring onto the No. 2 output shaft.

10. INSPECT 5TH DRIVEN GEAR THRUST CLEARANCE

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11. INSPECT 5TH DRIVEN GEAR RADIAL CLEARANCE

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12. INSTALL 6TH DRIVEN GEAR

    1. 

       Install the spacer into the No. 2 output shaft.

    2. 

       Coat the 2 pieces of the needle roller bearing with gear oil, and install them into the No. 2 output shaft.

    3. 

       Coat the 6th gear synchronizer ring with gear oil, and install it into the No. 3 transmission clutch hub.

    4. 

       Coat the 6th driven gear with gear oil, and install it into the No. 2 output shaft.

13. INSTALL REAR NO. 2 OUTPUT SHAFT BEARING

    1. 

       Using SST and press, press in the rear No. 2 output shaft bearing to the No. 2 output shaft.

       09710-04071

       Note:

       After installation, make sure that the gear and synchronizer ring move smoothly.

14. INSTALL NO. 2 OUTPUT SHAFT BEARING SNAP RING

    1. 

       *a

       Mark

       Select a new No. 2 output shaft bearing snap ring, using the table below, that makes the thrust clearance of the 6th driven gear less than 0.1 mm (0.00394 in.).

       Standard No. 2 output shaft bearing snap ring thickness

       Mark	Thickness	Mark	Thickness
       B	1.85 mm (0.0728 in.)	0	2.05 mm (0.0807 in.)
       C	1.90 mm (0.0748 in.)	1	2.10 mm (0.0827 in.)
       D	1.95 mm (0.0768 in.)	2	2.15 mm (0.0846 in.)
       E	2.00 mm (0.0787 in.)	-	-

    2. 

       Using a snap ring expander, install the No. 2 output shaft bearing snap ring onto the No. 2 output shaft.

15. INSPECT 6TH DRIVEN GEAR THRUST CLEARANCE

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16. INSPECT 6TH DRIVEN GEAR RADIAL CLEARANCE

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17. INSTALL FRONT NO. 2 OUTPUT SHAFT BEARING

    1. 

       Using SST and a press, press in the front No. 2 output shaft bearing into the No. 2 output shaft.

       09309-37010

       09506-30012

18. INSTALL FRONT OUTPUT SHAFT BEARING

    1. 

       Using SST and press, press in the front output shaft bearing into the No. 1 output shaft.

       09309-14040

19. INSTALL FRONT OUTPUT SHAFT BEARING SHAFT SNAP RING

    1. 

       Using a snap ring expander, install a new front output shaft bearing shaft snap ring into the No. 1 output shaft.

20. INSTALL 1ST DRIVEN GEAR

    1. 

       Coat the needle roller bearing with gear oil, and install it into the No. 1 output shaft.

    2. 

       Coat the 1st driven gear with gear oil, and install it into the No. 1 output shaft.

21. INSTALL NO. 1 TRANSMISSION CLUTCH HUB

    1. 

       Apply of gear oil to the sleeve and hub.

    2. Install the hub sleeve to the clutch hub.

    3. Install the 3 shifting keys to the clutch hub.

    4. Install the 3 shifting key springs to the clutch hub.

    5. Place the 3 balls in the holes of the shifting keys, and install the hub sleeve while pushing in the balls.

       Note:

       Take care to prevent the balls from scattering.

    6. 

       Coat the 3 pieces of the 1st driven gear synchronizer ring set with gear oil, and install them to the 1st driven gear.

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

       09726-40010

       Note:

       After installation, make sure that the gear and synchronizer ring move smoothly.

       Tip:

       Make sure that the protruding part on the synchronizer ring is fitted into the groove of the clutch hub.

22. INSTALL 2ND DRIVEN GEAR SYNCHRONIZER RING SET

    1. 

       Coat the 3 pieces of the 2nd driven gear synchronizer ring set with gear oil, and install them to the No. 1 output shaft.

23. INSTALL SYNCHROMESH SHIFTING KEY BALL

    

    1. Using a magnet hand, install the synchromesh shifting key ball onto the No. 1 output shaft.

24. INSTALL NEEDLE ROLLER BEARING

    1. 

       Coat the needle roller bearing with gear oil, and install it into the No. 1 output shaft.

25. INSTALL 2ND DRIVEN GEAR

    1. 

       Coat the 2nd driven gear with gear oil, and install it into the No. 1 output shaft.

26. INSTALL INNER 2ND DRIVEN GEAR BEARING RACE

    1. 

       Align the groove of the inner 2nd driven gear bearing race with the synchromesh shifting key ball, and install it.

27. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING

    1. 

       Using a snap ring expander, install the output shaft bearing shaft snap ring to the No. 1 output shaft.

       Tip:

       Do not damage the journal surface of the No. 1 output shaft.

28. INSTALL 4TH DRIVEN GEAR

    1. 

       Install the spacer into the No. 1 output shaft.

    2. 

       Coat the 2 pieces of the needle roller bearing with gear oil, and install them into the No. 1 output shaft.

    3. 

       Coat the 4th driven gear with gear oil, and install it into the No. 1 output shaft.

29. INSTALL NO. 2 TRANSMISSION CLUTCH HUB

    1. 

       Apply of gear oil to the sleeve and hub.

    2. Install the hub sleeve to the clutch hub.

    3. Install the 3 shifting keys to the clutch hub.

    4. Install the 3 shifting key springs to the clutch hub.

    5. Place the 3 balls in the holes of the shifting keys, and install the hub sleeve while pushing in the balls.

       Note:

       Take care to prevent the balls from scattering.

    6. Coat the 3 pieces of the 4th driven gear synchronizer ring set with gear oil, and install them into the 4th driven gear.

    7. 

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

       09309-14010

       Tip:

       Make sure that the protruding part on the synchronizer ring is fitted into the groove of the clutch hub.

       Note:

       After installation, make sure that the gear and synchronizer ring move smoothly.

30. INSTALL SHAFT SNAP RING

    1. 

       *a

       Mark

       Select a new shaft snap ring, using the table below, that makes the thrust clearance of the No. 2 transmission clutch hub less than 0.1 mm (0.00394 in.).

       Standard shaft snap ring thickness

       Mark	Thickness	Mark	Thickness
       1	2.25 mm (0.0886 in.)	4	2.40 mm (0.0945 in.)
       2	2.30 mm (0.0906 in.)	5	2.45 mm (0.0965 in.)
       3	2.35 mm (0.0925 in.)	6	2.50 mm (0.0984 in.)

    2. 

       Using a brass bar and hammer, tap the shaft snap ring into the No. 1 output shaft.

31. INSPECT 1ST DRIVEN GEAR THRUST CLEARANCE

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32. INSPECT 1ST DRIVEN GEAR RADIAL CLEARANCE

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33. INSPECT 2ND DRIVEN GEAR THRUST CLEARANCE

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34. INSPECT 2ND DRIVEN GEAR RADIAL CLEARANCE

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35. INSPECT 4TH DRIVEN GEAR THRUST CLEARANCE

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36. INSPECT 4TH DRIVEN GEAR RADIAL CLEARANCE

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37. INSTALL 3RD DRIVEN GEAR

    1. 

       Coat the 3rd driven gear synchronizer ring set with gear oil, and install it into the No. 1 output shaft.

    2. 

       Coat the needle roller bearing with gear oil, and install it into the No. 1 output shaft.

    3. 

       Install the spacer into the No. 1 output shaft.

    4. 

       Coat the 3rd driven gear with gear oil, and install it into the No. 1 output shaft.

38. INSTALL FRONT OUTPUT SHAFT BEARING

    1. 

       Using SST and press, press in the output shaft front bearing into the No. 1 output shaft.

       09308-14010

       Tip:

       When pressing in the bearing, apply force to only the inner race. Do not apply force to the seal.

       Note:

       After installation, make sure that the gear and synchronizer ring move smoothly.

39. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING

    1. 

       *a

       Mark

       Select a new output shaft bearing shaft snap ring, using the table below, that makes the thrust clearance of the output shaft bearing less than 0.1 mm (0.00394 in.).

       Standard output shaft bearing snap ring thickness

       Mark	Thickness	Mark	Thickness
       B	1.85 mm (0.0728 in.)	0	2.05 mm (0.0807 in.)
       C	1.90 mm (0.0748 in.)	1	2.10 mm (0.0827 in.)
       D	1.95 mm (0.0768 in.)	2	2.15 mm (0.0846 in.)
       E	2.00 mm (0.0787 in.)	-	-

    2. 

       Using a snap ring expander, install the output shaft bearing shaft snap ring onto the No. 1 output shaft.

40. INSPECT 3RD DRIVEN GEAR THRUST CLEARANCE

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41. INSPECT 3RD DRIVEN GEAR RADIAL CLEARANCE

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