Output Shaft Reassembly

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

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

Install the key spring and 2 shifting keys to the clutch hub.

УКАЗАНИЕ:

1. Install the shifting key with the grooves on the clutch hub side.
   
2. Install the key spring with the claw on the clutch hub side.
   
3. Refer to the illustration when installing the key spring and shifting keys.
   

Install the hub sleeve to the reverse driven gear as shown in the illustration.

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

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

Специальный инструмент (SST):

09308-14010

ПРИМЕЧАНИЕ:

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

УКАЗАНИЕ:

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

Using the table below, select a new snap ring that makes the thrust clearance of the No. 4 transmission clutch hub less than 0.1 mm (0.004 in.).

Standard snap ring thickness:

Mark	Thickness	Mark	Thickness
A	2.25 to 2.30 mm (0.0886 to 0.0906 in.)	E	2.45 to 2.50 mm (0.0965 to 0.0984 in.)
B	2.30 to 2.35 mm (0.0906 to 0.0925 in.)	F	2.50 to 2.55 mm (0.0984 to 0.1004 in.)
C	2.35 to 2.40 mm (0.0925 to 0.0945 in.)	G	2.55 to 2.60 mm (0.1004 to 0.1024 in.)
D	2.40 to 2.45 mm (0.0945 to 0.0965 in.)	H	2.60 to 2.65 mm (0.1024 to 0.1043 in.)

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

Using a feeler gauge, measure the thrust clearance.

Standard thrust clearance:

0.11 to 0.34 mm (0.0043 to 0.0134 in.)

Maximum thrust clearance:

0.34 mm (0.0134 in.)

Using a dial indicator, measure the radial clearance.

Standard radial clearance:

0.015 to 0.068 mm (0.0006 to 0.0027 in.)

Maximum radial clearance:

0.068 mm (0.0027 in.)

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

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

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

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

Apply gear oil to the sleeve and hub.

Install the clutch hub sleeve to the clutch hub.

Install the 3 shifting keys to the clutch hub.

Install the 3 shifting key springs to the clutch hub.

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

ПРИМЕЧАНИЕ:

Take care to prevent the balls from scattering.

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

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

Специальный инструмент (SST):

09308-14010

ПРИМЕЧАНИЕ:

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

УКАЗАНИЕ:

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

Using the table below, select a new snap ring that makes the thrust clearance of the No. 3 transmission clutch hub less than 0.1 mm (0.004 in.).

Standard snap ring thickness:

Mark	Thickness	Mark	Thickness
1	2.25 to 2.30 mm (0.0886 to 0.0906 in.)	4	2.40 to 2.45 mm (0.0945 to 0.0965 in.)
2	2.30 to 2.35 mm (0.0906 to 0.0925 in.)	5	2.45 to 2.50 mm (0.0965 to 0.0984 in.)
3	2.35 to 2.40 mm (0.0925 to 0.0945 in.)	6	2.50 to 2.55 mm (0.0984 to 0.1004 in.)

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

Using a feeler gauge, measure the thrust clearance.

Standard thrust clearance:

0.10 to 0.55 mm (0.0039 to 0.0217 in.)

Maximum thrust clearance:

0.55 mm (0.0217 in.)

Using a dial indicator, measure the radial clearance.

Standard radial clearance:

0.015 to 0.066 mm (0.0006 to 0.0026 in.)

Maximum radial clearance:

0.066 mm (0.0026 in.)

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

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

Coat the synchronizer ring with gear oil, and install it into the transmission clutch hub.

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

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

Специальный инструмент (SST):

09710-04071

ПРИМЕЧАНИЕ:

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

Using the table below, select a new snap ring that makes the thrust clearance of the 6th gear less than 0.1 mm (0.004 in.).

Standard snap ring thickness:

Mark	Thickness	Mark	Thickness
B	1.85 to 1.90 mm (0.0728 to 0.0748 in.)	0	2.05 to 2.10 mm (0.0807 to 0.0827 in.)
C	1.90 to 1.95 mm (0.0748 to 0.0768 in.)	1	2.10 to 2.15 mm (0.0827 to 0.0846 in.)
D	1.95 to 2.00 mm (0.0768 to 0.0787 in.)	2	2.15 to 2.20 mm (0.0846 to 0.0866 in.)
E	2.00 to 2.05 mm (0.0787 to 0.0807 in.)	-	-

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

Using a feeler gauge, measure the thrust clearance.

Standard thrust clearance:

0.10 to 0.55 mm (0.0039 to 0.0217 in.)

Maximum thrust clearance:

0.55 mm (0.0217 in.)

Using a dial indicator, measure the radial clearance.

Standard radial clearance:

0.015 to 0.066 mm (0.0006 to 0.0026 in.)

Maximum radial clearance:

0.066 mm (0.0026 in.)

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

Специальный инструмент (SST):

09309-37010
09506-30012

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

Специальный инструмент (SST):

09309-14040

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

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

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

Apply gear oil to the sleeve and hub.

Install the clutch hub sleeve to the clutch hub.

Install the 3 shifting keys to the clutch hub.

Install the 3 shifting key springs to the clutch hub.

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

ПРИМЕЧАНИЕ:

Take care to prevent the balls from scattering.

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

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

Специальный инструмент (SST):

09726-40010

ПРИМЕЧАНИЕ:

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

УКАЗАНИЕ:

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

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

Install the key ball onto the No. 1 output shaft.

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

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

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

Using the table below, select a new snap ring that makes the thrust clearance of the 2nd gear less than 0.1 mm (0.004 in.).

Standard snap ring thickness:

Mark	Thickness	Mark	Thickness
A	2.25 to 2.30 mm (0.0886 to 0.0906 in.)	E	2.45 to 2.50 mm (0.0965 to 0.0984 in.)
B	2.30 to 2.35 mm (0.0906 to 0.0925 in.)	F	2.50 to 2.55 mm (0.0984 to 0.1004 in.)
C	2.35 to 2.40 mm (0.0925 to 0.0945 in.)	G	2.55 to 2.60 mm (0.1004 to 0.1024 in.)
D	2.40 to 2.45 mm (0.0945 to 0.0965 in.)	H	2.60 to 2.65 mm (0.1024 to 0.1043 in.)

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

Using a dial indicator, measure the thrust clearance.

Standard thrust clearance:

0.10 to 0.35 mm (0.0039 to 0.0138 in.)

Maximum thrust clearance:

0.35 mm (0.0138 in.)

Using a dial indicator, measure the radial clearance.

Standard radial clearance:

0.015 to 0.068 mm (0.0006 to 0.0027 in.)

Maximum radial clearance:

0.068 mm (0.0027 in.)

Using a dial indicator, measure the thrust clearance.

Standard thrust clearance:

0.11 to 0.46 mm (0.0043 to 0.0181 in.)

Maximum thrust clearance:

0.46 mm (0.0181 in.)

Using a dial indicator, measure the radial clearance.

Standard radial clearance:

0.015 to 0.048 mm (0.0006 to 0.0019 in.)

Maximum radial clearance:

0.048 mm (0.0019 in.)

Install the output shaft spacer into the No. 1 output shaft.

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

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

Apply gear oil to the sleeve and hub.

Install the clutch hub sleeve to the clutch hub.

Install the 3 shifting keys to the clutch hub.

Install the 3 shifting key springs to the clutch hub.

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

ПРИМЕЧАНИЕ:

Take care to prevent the balls from scattering.

Coat the 4th driven gear synchronizer ring set with gear oil.

Using SST and a press, press the clutch hub into the 4th driven gear.

Специальный инструмент (SST):

09309-14010

ПРИМЕЧАНИЕ:

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

УКАЗАНИЕ:

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

Using the table below, select a new snap ring that makes the thrust clearance of the No. 2 transmission clutch hub less than 0.1 mm (0.004 in.).

Standard snap ring thickness:

Mark	Thickness	Mark	Thickness
1	2.25 to 2.30 mm (0.0886 to 0.0906 in.)	4	2.40 to 2.45 mm (0.0945 to 0.0965 in.)
2	2.30 to 2.35 mm (0.0906 to 0.0925 in.)	5	2.45 to 2.50 mm (0.0965 to 0.0984 in.)
3	2.35 to 2.40 mm (0.0925 to 0.0945 in.)	6	2.50 to 2.55 mm (0.0984 to 0.1004 in.)

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

Using a feeler gauge, measure the thrust clearance.

Standard thrust clearance:

0.10 to 0.65 mm (0.0039 to 0.0256 in.)

Maximum thrust clearance:

0.65 mm (0.0256 in.)

Using a dial indicator, measure the radial clearance.

Standard radial clearance:

0.015 to 0.066 mm (0.0006 to 0.0026 in.)

Maximum radial clearance:

0.066 mm (0.0026 in.)

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

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

Install the output shaft spacer into the No. 1 output shaft.

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

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

Специальный инструмент (SST):

09308-14010

УКАЗАНИЕ:

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

ПРИМЕЧАНИЕ:

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

Using the table below, select a new snap ring that makes the thrust clearance of the output shaft bearing less than 0.1 mm (0.004 in.).

Standard snap ring thickness:

Mark	Thickness	Mark	Thickness
B	1.85 to 1.90 mm (0.0728 to 0.0748 in.)	0	2.05 to 2.10 mm (0.0807 to 0.0827 in.)
C	1.90 to 1.95 mm (0.0748 to 0.0768 in.)	1	2.10 to 2.15 mm (0.0827 to 0.0846 in.)
D	1.95 to 2.00 mm (0.0768 to 0.0787 in.)	2	2.15 to 2.20 mm (0.0846 to 0.0866 in.)
E	2.00 to 2.05 mm (0.0787 to 0.0807 in.)	-	-

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

Using a feeler gauge, measure the thrust clearance.

Standard thrust clearance:

0.11 to 0.54 mm (0.0043 to 0.0213 in.)

Maximum thrust clearance:

0.54 mm (0.0213 in.)

Using a dial indicator, measure the radial clearance.

Standard radial clearance:

0.015 to 0.066 mm (0.0006 to 0.0026 in.)

Maximum radial clearance:

0.066 mm (0.0026 in.)