Output Shaft Installation

Coat the hub sleeve with gear oil, and install it to the clutch hub.

NOTICE:

Be sure to set the hub sleeve to the clutch hub in the correct direction.

Install the 3 synchromesh shifting keys to the clutch hub with the 2 synchromesh shifting key springs.

HINT:

Do not set both openings of the shifting key springs in the same position.

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

Coat the 3rd gear with gear oil, and install it to the output shaft.

Coat the synchronizer ring with gear oil, and install it to the 3rd gear.

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

SST

09316-60011(09316-00021)

Select a clutch hub shaft snap ring that will allow minimal axial play.

Standard clearance:

0.10 mm (0.039 in.) or less

Standard clutch hub shaft snap ring thickness:

Mark	Thickness
C-1	1.75 to 1.80 mm (0.0689 to 0.0709 in.)
D	1.80 to 1.85 mm (0.0709 to 0.0728 in.)
D-1	1.85 to 1.90 mm (0.0728 to 0.0748 in.)
E	1.90 to 1.95 mm (0.0748 to 0.0768 in.)
E-1	1.95 to 2.00 mm (0.0768 to 0.0787 in.)
F	2.00 to 2.05 mm (0.0787 to 0.0807 in.)
F-1	2.05 to 2.10 mm (0.0807 to 0.0827 in.)

Using a snap ring expander, install the snap ring.

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.0039 to 0.0098in.)

Coat the reverse gear with gear oil, and install it to the clutch hub.

NOTICE:

Be sure to set the reverse gear to the clutch hub in the correct direction.

Install 3 synchromesh shifting keys to the clutch hub with the 2 synchromesh shifting key springs.

HINT:

Do not set both openings of the shifting key springs in the same position.

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

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

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

Using SST and a press, press in the clutch hub to the output shaft.

SST

09316-60011

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.10 to 0.250 mm (0.0039 to 0.0098 in.)

Coat the synchronizer ring with gear oil, and install it to the No. 1 clutch hub.

Coat the lock ball with gear oil, and install it to the output shaft.

Coat the needle roller bearing with gear oil.

Install the inner race and needle roller bearing to the 1st gear.

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

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

SST

09316-60011(09316-00021)

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.0039 to 0.0078 in.)

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

SST

09316-60011(09316-00021)

Select a snap ring that will allow minimal axial play.

Standard clearance:

0.10 mm (0.039 in.) or less

Standard output shaft bearing shaft snap ring:

Mark	Thickness
A	2.67 to 2.72 mm (0.1051 to 0.1071 in.)
B	2.73 to 2.78 mm (0.1075 to 0.1094 in.)
C	2.79 to 2.84 mm (0.1098 to 0.1118 in.)
D	2.85 to 2.90 mm (0.1122 to 0.1141 in.)
E	2.91 to 2.96 mm (0.1146 to 0.1165 in.)
F	2.97 to 3.02 mm (0.1169 to 0.1189 in.)
G	3.03 to 3.08 mm (0.1193 to 0.1213 in.)
H	3.09 to 3.14 mm (0.1217 to 0.1236 in.)
J	3.15 to 3.20 mm (0.1240 to 0.1260 in.)
K	3.21 to 3.26 mm (0.1264 to 0.1283 in.)
L	3.27 to 3.32 mm (0.1287 to 0.1307 in.)

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

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.008 to 0.034 mm (0.0003 to 0.0013 in.)

1. If the clearance is not as specified, replace the needle roller bearing.
   

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.008 to 0.034 mm (0.0003 to 0.0013 in.)

1. If the clearance is not as specified, replace the needle roller bearing.
   

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.009 to 0.056 mm (0.0004 to 0.0022 in.)

1. If the clearance is not as specified, replace the needle roller bearing.