Output Shaft (For Sedan) Reassembly

Coat the reverse gear with gear oil and install it onto transmission clutch hob No. 1.

NOTICE:

Orient the reverse gear and transmission clutch hub No. 1 correctly.

Install the 3 synchromesh shifting key springs and 3 synchromesh keys onto transmission clutch hub No. 1.

Coat the 1st gear thrust washer pin or ball with MP grease, and install it onto the output shaft.

Coat the 1st gear thrust washer with gear oil and install it onto the output shaft.

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

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

Coat synchronizer ring No. 1 with gear oil and install it onto the 1st gear.

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

SST

09316-60011(09316-00031)

HINT:

1. The 1st gear can be turned.
   
2. While checking that the 1st gear thrust washer pin or ball is inserted into the groove of the 1st gear thrust washer, press and fit the clutch hub No. 1.
   

Select a snap ring that will allow minimum axial play.

Standard clearance:

0.1 mm (0.039 in.) or less

Snap ring thickness:

Mark	Thickness mm (in.)	Mark	Thickness mm (in.)
A	2.50 (0.0984)	D	2.68 (0.1055)
B	2.56 (0.1008)	E	2.74 (0.1079)
C	2.62 (0.1031)	F	2.80 (0.1102)

Using a brass bar and a hammer, install the snap ring onto the output shaft.

NOTICE:

Do not damage the journal surface of the output shaft.

Coat the 2nd gear needle roller bearing and 2nd gear bearing spacer with gear oil, and install them onto the output shaft.

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

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

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

SST

09316-60011(09316-00031)

Install the output gear spacer onto the output shaft.

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

SST

09612-22011

Using SST and a press, install the output shaft rear bearing onto the output shaft.

SST

09612-22011

Using a dial gauge, measure the 2nd gear radial clearance between the gear and shaft.

Standard clearance:

KOYO made:

0.015 to 0.058 mm (0.0006 to 0.0023 in.)

NSK made:

0.015 to 0.056 mm (0.0006 to 0.0022 in.)

Maximum clearance:

KOYO made:

0.058 mm (0.0023 in.)

NSK made:

0.056 mm (0.0022 in.)

Using a dial gauge, measure the 1st gear radial clearance between the gear and shaft.

Standard clearance:

KOYO made:

0.015 to 0.058 mm (0.0006 to 0.0023 in.)

NSK made:

0.015 to 0.056 mm (0.0006 to 0.0022 in.)

Maximum clearance:

KOYO made:

0.058 mm (0.0023 in.)

NSK made:

0.056 mm (0.0022 in.)

Using a dial gauge, measure the 2nd gear thrust clearance.

Standard clearance:

0.10 to 0.55 mm (0.0039 to 0.0217 in.)

Maximum clearance:

0.55 mm (0.0217 in.)

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

Standard clearance:

0.10 to 0.40 mm (0.0039 to 0.0157 in.)

Maximum clearance:

0.40 mm (0.0157 in.)