OUTPUT SHAFT > REASSEMBLY

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1. INSTALL NEEDLE ROLLER BEARING


    C112406

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



2. INSTALL REVERSE DRIVEN GEAR


    C116717

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



3. INSTALL NO. 4 TRANSMISSION CLUTCH HUB


    C116552E02

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

    HINT:
    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.

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



    C116199E01

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

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

    SST
    09308-14010  

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

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


4. INSTALL SHAFT SNAP RING


    C118746E01

  1. 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.)


    C112456

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



5. INSPECT REVERSE DRIVEN GEAR THRUST CLEARANCE


    C113606

  1. 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.)
    If the thrust clearance exceeds the maximum, replace the reverse driven gear, needle roller bearing or shaft.


6. INSPECT REVERSE DRIVEN GEAR RADIAL CLEARANCE


    C113607

  1. 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.)
    If the radial clearance exceeds the maximum, replace the reverse driven gear, needle roller bearing or shaft.


7. INSTALL 5TH DRIVEN GEAR


    C112402

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



    C112401

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



    C112400

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



    C116206

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



8. INSTALL NO. 3 TRANSMISSION CLUTCH HUB


    C116553

  1. Apply gear oil to the sleeve and hub.

  1. Install the clutch hub sleeve to the clutch hub.

  1. Install the 3 shifting keys to the clutch hub.

  1. Install the 3 shifting key springs to the clutch hub.

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

    NOTICE:
    Take care to prevent the balls from scattering.


    C116200E01

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

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

    SST
    09308-14010  

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

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


9. INSTALL SHAFT SNAP RING


    C118747E02

  1. 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.)


    C112462

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



10. INSPECT 5TH DRIVEN GEAR THRUST CLEARANCE


    C113604

  1. 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.)
    If the thrust clearance exceeds the maximum, replace the 5th driven gear, needle roller bearing or shaft.


11. INSPECT 5TH DRIVEN GEAR RADIAL CLEARANCE


    C113605

  1. 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.)
    If the radial clearance exceeds the maximum, replace the 5th driven gear, needle roller bearing or shaft.


12. INSTALL 6TH DRIVEN GEAR


    C116203

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



    C116204

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



    C116202

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



    C116555

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



13. INSTALL NO. 2 OUTPUT SHAFT REAR BEARING


    C112458E01

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

    SST
    09710-04071  

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


14. INSTALL NO. 2 OUTPUT SHAFT BEARING SNAP RING


    C118748E01

  1. 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.)
    		-
    		-


    C112395

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



15. INSPECT 6TH DRIVEN GEAR THRUST CLEARANCE


    C113602

  1. 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.)
    If the thrust clearance exceeds the maximum, replace the 6th driven gear, needle roller bearing or shaft.


16. INSPECT 6TH DRIVEN GEAR RADIAL CLEARANCE


    C113603

  1. 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.)
    If the radial clearance exceeds the maximum, replace the 6th driven gear, needle roller bearing or shaft.


17. INSTALL NO. 2 OUTPUT SHAFT FRONT BEARING


    C112459E01

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

    SST
    09309-37010  
    09506-30012  


18. INSTALL OUTPUT SHAFT FRONT BEARING


    C112466E01

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

    SST
    09309-14040  


19. INSTALL OUTPUT SHAFT FRONT BEARING SHAFT SNAP RING


    C112426

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



20. INSTALL 1ST DRIVEN GEAR


    C112425

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



    C116554

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



21. INSTALL NO. 1 TRANSMISSION CLUTCH HUB


    C116550

  1. Apply gear oil to the sleeve and hub.

  1. Install the clutch hub sleeve to the clutch hub.

  1. Install the 3 shifting keys to the clutch hub.

  1. Install the 3 shifting key springs to the clutch hub.

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

    NOTICE:
    Take care to prevent the balls from scattering.


    C112467E01

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

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

    SST
    09726-40010  

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

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


22. INSTALL 2ND DRIVEN GEAR SYNCHRONIZER RING SET


    C112422

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



23. INSTALL SYNCHROMESH SHIFTING KEY BALL


    C116562

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



24. INSTALL NEEDLE ROLLER BEARING


    C112421

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



25. INSTALL 2ND DRIVEN GEAR


    C112420

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



26. INSTALL 2ND DRIVEN GEAR BEARING INNER RACE


    C112419

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



27. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING


    C118749E01

  1. 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.)


    C112418

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



28. INSPECT 1ST DRIVEN GEAR THRUST CLEARANCE


    C115414

  1. 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.)
    If the thrust clearance exceeds the maximum, replace the 1st driven gear, needle roller bearing or shaft.


29. INSPECT 1ST DRIVEN GEAR RADIAL CLEARANCE


    C115416

  1. 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.)
    If the radial clearance exceeds the maximum, replace the 1st driven gear, needle roller bearing or shaft.


30. INSPECT 2ND DRIVEN GEAR THRUST CLEARANCE


    C115415

  1. 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.)
    If the thrust clearance exceeds the maximum, replace the 2nd driven gear, needle roller bearing or shaft.


31. INSPECT 2ND DRIVEN GEAR RADIAL CLEARANCE


    C113596

  1. 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.)
    If the radial clearance exceeds the maximum, replace the 2nd driven gear, needle roller bearing or shaft.


32. INSTALL 4TH DRIVEN GEAR


    C112417

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



    C112416

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



    C116209

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



33. INSTALL NO. 2 TRANSMISSION CLUTCH HUB


    C116551

  1. Apply gear oil to the sleeve and hub.

  1. Install the clutch hub sleeve to the clutch hub.

  1. Install the 3 shifting keys to the clutch hub.

  1. Install the 3 shifting key springs to the clutch hub.

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

    NOTICE:
    Take care to prevent the balls from scattering.


    C112468E01

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

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

    SST
    09309-14010  

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

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


34. INSTALL SHAFT SNAP RING


    C118750E02

  1. 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.)


    C112469

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



35. INSPECT 4TH DRIVEN GEAR THRUST CLEARANCE


    C113640

  1. 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.)
    If the thrust clearance exceeds the maximum, replace the 4th driven gear, needle roller bearing or shaft.


36. INSPECT 4TH DRIVEN GEAR RADIAL CLEARANCE


    C113644

  1. 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.)
    If the radial clearance exceeds the maximum, replace the 4th driven gear, needle roller bearing or shaft.


37. INSTALL 3RD DRIVEN GEAR


    C112413

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



    C112412

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



    C112411

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



    C112410

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



38. INSTALL OUTPUT SHAFT FRONT BEARING


    C112465E02

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

    SST
    09308-14010  

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

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


39. INSTALL OUTPUT SHAFT BEARING SHAFT SNAP RING


    C118751E02

  1. 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.)
    		-
    		-


    C112408

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



40. INSPECT 3RD DRIVEN GEAR THRUST CLEARANCE


    C113639

  1. 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.)
    If the thrust clearance exceeds the maximum, replace the 3rd driven gear, needle roller bearing or shaft.


41. INSPECT 3RD DRIVEN GEAR RADIAL CLEARANCE


    C113643

  1. 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.)
    If the radial clearance exceeds the maximum, replace the 3rd driven gear, needle roller bearing or shaft.