Output Shaft Reassembly

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

NOTICE:

Make sure that the No. 2 hub sleeve and No. 2 clutch hub are installed facing the proper directions.

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

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

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

Apply gear oil to the No. 2 synchronizer ring and install it to the 3rd gear.

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

SST

09608-06041

NOTICE:

1. Install the hub while aligning the positions of the shifting keys with the key grooves of the No. 2 synchronizer ring.
   
2. Make sure the 3rd gear rotates smoothly.
   

Select a snap ring that makes the clearance between the No. 2 clutch hub and snap ring within the specification.

Standard clearance:

0.10 mm (0.00394 in.) or less

Snap Ring Thickness:

Thickness

1.80 mm (0.0709 in.)

1.85 mm (0.0728 in.)

1.90 mm (0.0748 in.)

1.95 mm (0.0768 in.)

2.00 mm (0.0787 in.)

2.05 mm (0.0807 in.)

2.10 mm (0.0827 in.)

Using a snap ring expander, install the snap ring.

NOTICE:

Do not damage the sliding surface of the bearing.

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

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

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

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

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

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

SST

09316-60011(09316-00041)

NOTICE:

1. Make sure that the No. 1 synchromesh shifting key positions are aligned with the No. 1 synchronizer ring key grooves.
   
2. Make sure the 1st gear rotates freely.
   

Select a snap ring that makes the thrust clearance between the No. 1 clutch hub and snap ring to be within the specification.

Standard clearance:

0.1 mm (0.00394 in.) or less

NOTICE:

Do not damage the journal surface of the snap ring.

Snap Ring Thickness:

Thickness

2.30 mm (0.0906 in.)

2.35 mm (0.0925 in.)

2.40 mm (0.0945 in.)

2.45 mm (0.0965 in.)

2.50 mm (0.0984 in.)

2.55 mm (0.1004 in.)

2.60 mm (0.1024 in.)

Using a brass bar and hammer, tap on the snap ring.

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

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

Install the thrust washer pin to the output shaft.

Apply gear oil to the No. 1 synchronizer ring set and install it to the output shaft.

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

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

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

SST

09316-60011(09316-00031)

NOTICE:

Install the center bearing so that the snap ring groove of the bearing faces the rear side.

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

SST

09316-60011(09316-00031)

NOTICE:

1. Check that the 5th gear and the splines of the output shaft fit before installing the 5th gear.
   
2. Make sure face the convex part of the gear faces the front side.
   

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.20 to 0.45 mm (0.00787 to 0.0177 in.)

1. If the clearance is not as specified, replace the No. 1 synchronizer ring set.
   

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.00394 to 0.00984 in.)

1. If the clearance is not as specified, replace the No. 1 synchronizer ring set.
   

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.00394 to 0.00984 in.)

1. If the clearance is not as specified, replace the No. 2 synchronizer ring set.
   

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.020 to 0.073 mm (0.000785 to 0.00287 in.)

1. If the clearance is not as specified, replace the 1st gear needle roller bearing with a new one.
   

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.015 to 0.068 mm (0.000591 to 0.00267 in.)

1. If the clearance is not as specified, replace the 2nd gear needle roller bearing with a new one.
   

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.015 to 0.068 mm (0.000591 to 0.00267 in.)

1. If the clearance is not as specified, replace the 3rd gear needle roller bearing with a new one.