OUTPUT SHAFT (for Hatchback) > REASSEMBLY

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1. INSTALL REVERSE GEAR


C068241
  1. 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.
  1. 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


C068014
  1. 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


C068013
  1. 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


C068012
  1. Coat the 1st gear needle roller bearing with gear oil and install it onto the output shaft.



5. INSTALL 1ST GEAR


C068310
  1. Coat the 1st gear with gear oil and install it onto the output shaft.



6. INSTALL NO. 1 SYNCHRONIZER RING (FOR 1ST GEAR)


    C068311
  1. Coat the No. 1 synchronizer ring with gear oil and install it onto the 1st gear.



7. INSTALL NO. 1 TRANSMISSION CLUTCH HUB


C080547E01
  1. Using SST and a press, install the No. 1 transmission clutch hub 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 No. 1 clutch hub.


    C068244
  1. 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)
  1. 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


    C068246
  1. 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)
  1. Coat the No. 1 synchronizer ring with gear oil.



    C157314
  1. Install the No. 1 synchronizer inner ring onto the 2nd gear.



    C157315
  1. Install the No. 1 synchronizer middle ring onto the 2nd gear.



    C157316
  1. Install the No. 1 synchronizer outer ring onto the 2nd gear.



10. INSTALL 2ND GEAR


C068248
  1. Coat the 2nd gear with gear oil and install it onto the output shaft.



11. INSTALL 3RD DRIVEN GEAR


C080548E01
  1. Using SST and a press, install the 3rd driven gear onto the output shaft.

    SST
    09316-60011   (09316-00031)


12. INSTALL OUTPUT GEAR SPACER


C068005
  1. Install the output gear spacer onto the output shaft.



13. INSTALL 4TH DRIVEN GEAR


C082013E01
  1. Using SST and a press, install the 4th driven gear onto the output shaft.

    SST
    09612-22011  


14. INSTALL OUTPUT SHAFT REAR BEARING


C082014E01
  1. Using SST and a press, install the output shaft rear bearing onto the output shaft.

    SST
    09612-22011  


15. INSPECT 2ND GEAR RADIAL CLEARANCE


C068254
  1. 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.)
    If the clearance exceeds the maximum, replace the 2nd gear or 2nd gear needle roller bearing.


16. INSPECT 1ST GEAR RADIAL CLEARANCE


C068309
  1. 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.)
    If the clearance exceeds the maximum, replace the 1st gear or 1st gear needle roller bearing.


17. INSPECT 2ND GEAR THRUST CLEARANCE


C068312
  1. 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.)
    If the clearance exceeds the maximum, replace the No. 1 transmission clutch hub, 2nd gear, or 3rd driven gear.


18. INSPECT 1ST GEAR THRUST CLEARANCE


C080538
  1. 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.)
    If the clearance exceeds the maximum, replace the 1st gear thrust washer, 1st gear, or No. 1 transmission clutch hub.