Output Shaft Installation

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

NOTICE:

Be careful of the directions of the No. 2 hub sleeve and No. 2 clutch hub.

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, press in the No. 2 clutch hub to the output shaft.

SST

09608-06041

NOTICE:

1. Install the hub while aligning the key groove of the hub and the shifting key position.
   
2. The 3rd gear should be able to rotate smoothly.
   

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

Standard clearance:

0.10 mm (0.0039 in.) or less

NOTICE:

Do not damage the sliding surface of the bearing.

Standard snap ring thickness:

Mark	Thickness
A	1.80 to 1.85 mm (0.0709 to 0.0728 in.)
B	1.85 to 1.90 mm (0.0728 to 0.0748 in.)
C	1.90 to 1.95 mm (0.0748 to 0.0768 in.)
D	1.95 to 2.00 mm (0.0768 to 0.0787 in.)
E	2.00 to 2.05 mm (0.0787 to 0.0807 in.)
F	2.05 to 2.10 mm (0.0807 to 0.0827 in.)
G	2.10 to 2.15 mm (0.0827 to 0.0846 in.)

Using a snap ring expander, install the snap ring.

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, press in the No. 1 clutch hub to the output shaft.

SST

09316-60011(09316-00041)

NOTICE:

1. While performing the step above, make sure that the No. 1 synchronizer ring key groove and No. 1 synchromesh shifting key position are aligned.
   
2. The 1st gear should rotate freely.
   

Select a snap ring so that the thrust clearance between the No. 1 clutch hub and snap ring is within the specification.

Standard clearance:

0.10 mm (0.039 in.) or less

NOTICE:

Do not damage the sliding surface of the bearing.

Standard snap ring thickness:

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

Using a brass bar and hammer, tap in 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 them 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, press in 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 to the rear side.

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

SST

09316-60011(09316-00031)

NOTICE:

1. Check that the 5th gear and the spline of the output shaft fit before installing it.
   
2. Face the convex part of the gear to the front side.
   

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.20 to 0.45 mm (0.0079 to 0.0177 in.)

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.0039 to 0.0098 in.)

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.0039 to 0.0098 in.)

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.020 to 0.073 mm (0.0008 to 0.00029 in.)

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.015 to 0.068 mm (0.0006 to 0.0027 in.)

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.015 to 0.068 mm (0.0006 to 0.0027 in.)