OUTPUT SHAFT (for Hatchback) > REASSEMBLY |
for Preparation Click here
1. INSTALL REVERSE GEAR |
Coat the reverse gear with gear oil and install it onto the No. 1 transmission clutch hub.
- NOTICE:
- Orient the reverse gear and No. 1 transmission clutch hub correctly.
Install the 3 synchromesh shifting key springs and 3 synchromesh keys onto the No. 1 transmission clutch hub.
2. INSTALL 1ST GEAR THRUST WASHER PIN OR BALL |
Coat the 1st gear thrust washer pin or ball with MP grease, and install it onto the output shaft.
3. INSTALL 1ST GEAR THRUST WASHER |
Coat the 1st gear thrust washer with gear oil and install it onto the output shaft.
- HINT:
- Fit the 1st gear thrust washer pin or ball into the groove of the 1st gear thrust washer correctly.
4. INSTALL 1ST GEAR NEEDLE ROLLER BEARING |
Coat the 1st gear needle roller bearing with gear oil and install it onto the output shaft.
5. INSTALL 1ST GEAR |
Coat the 1st gear with gear oil and install it onto the output shaft.
6. INSTALL NO. 1 SYNCHRONIZER RING (FOR 1ST GEAR) |
Coat the No. 1 synchronizer ring with gear oil and install it onto the 1st gear.
7. INSTALL NO. 1 TRANSMISSION CLUTCH HUB |
Using SST and a press, install the No. 1 transmission clutch hub onto the output shaft.
- SST
- 09316-60011
(09316-00031)
- HINT:
- The 1st gear can be turned.
- 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 No. 1 clutch hub.
Select a snap ring that will allow minimum axial play.
- Standard clearance:
- 0.1 mm (0.039 in.) or less
- Snap Ring Thickness:
Part No. Mark Thickness mm (in.) 09520-29018 A 2.50 (0.0984) 09520-29019 B 2.56 (0.1008) 09520-29020 C 2.62 (0.1031) 09520-29021 D 2.68 (0.1055) 09520-29022 E 2.74 (0.1079) 09520-29023 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.
8. INSTALL 2ND GEAR NEEDLE ROLLER BEARING |
Coat the 2nd gear needle roller bearing and 2nd gear bearing spacer with gear oil, and install them onto the output shaft.
9. INSTALL NO. 1 SYNCHRONIZER RING (FOR 2ND GEAR) |
Coat the No. 1 synchronizer ring with gear oil.
Install the No. 1 synchronizer inner ring onto the 2nd gear.
Install the No. 1 synchronizer middle ring onto the 2nd gear.
Install the No. 1 synchronizer outer ring onto the 2nd gear.
10. INSTALL 2ND GEAR |
Coat the 2nd gear with gear oil and install it onto the output shaft.
11. INSTALL 3RD DRIVEN GEAR |
Using SST and a press, install the 3rd driven gear onto the output shaft.
- SST
- 09316-60011
(09316-00031)
12. INSTALL OUTPUT GEAR SPACER |
Install the output gear spacer onto the output shaft.
13. INSTALL 4TH DRIVEN GEAR |
Using SST and a press, install the 4th driven gear onto the output shaft.
- SST
- 09612-22011
14. INSTALL OUTPUT SHAFT REAR BEARING |
Using SST and a press, install the output shaft rear bearing onto the output shaft.
- SST
- 09612-22011
15. INSPECT 2ND GEAR RADIAL CLEARANCE |
Using a dial indicator, measure the 2nd gear radial clearance between the gear and shaft.
- Standard clearance:
- JTEKT made:
- 0.015 to 0.058 mm (0.000591 to 0.00228 in.)
- NSK made:
- 0.015 to 0.056 mm (0.000591 to 0.00220 in.)
- Maximum clearance:
- JTEKT made:
- 0.058 mm (0.00228 in.)
- NSK made:
- 0.056 mm (0.00220 in.)
16. INSPECT 1ST GEAR RADIAL CLEARANCE |
Using a dial indicator, measure the 1st gear radial clearance between the gear and shaft.
- Standard clearance:
- JTEKT made:
- 0.015 to 0.058 mm (0.000591 to 0.00228 in.)
- NSK made:
- 0.015 to 0.056 mm (0.000591 to 0.00220 in.)
- Maximum clearance:
- JTEKT made:
- 0.058 mm (0.00228 in.)
- NSK made:
- 0.056 mm (0.00220 in.)
17. INSPECT 2ND GEAR THRUST CLEARANCE |
Using a dial indicator, measure the 2nd gear thrust clearance.
- Standard clearance:
- 0.10 to 0.55 mm (0.00394 to 0.0217 in.)
- Maximum clearance:
- 0.55 mm (0.0217 in.)
18. INSPECT 1ST GEAR THRUST CLEARANCE |
Using a feeler gauge, measure the 1st gear thrust clearance.
- Standard clearance:
- 0.10 to 0.40 mm (0.00394 to 0.0157 in.)
- Maximum clearance:
- 0.40 mm (0.0157 in.)