OUTPUT SHAFT > REASSEMBLY

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1. INSTALL FRONT OUTPUT SHAFT BEARING


    C194384E01

  1. Using SST and a press, install a new front output shaft bearing onto the output shaft.

    SST
    09309-14040  
    09612-22011  



2. INSTALL 1ST GEAR BUSH


    C194368

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



3. INSTALL 1ST GEAR NEEDLE ROLLER BEARING


    C194367

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



4. INSTALL 1ST GEAR


    C194385E01

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

    NOTICE:
    Install the 1st gear as shown in the illustration.



5. INSTALL NO. 1 SYNCHRONIZER RING SET (FOR 1ST GEAR)

  1. Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.



    C194386

  1. Install the inner ring onto the 1st gear.

  1. Install the middle ring onto the 1st gear.

    NOTICE:
    Engage the claws of the middle ring to the grooves of the 1st gear.

  1. Install the outer ring onto the 1st gear.

    NOTICE:
    Align the claws of the inner ring with the grooves of the outer ring, before installing the outer ring.



6. INSTALL NO. 1 TRANSMISSION CLUTCH HUB


    C194387

  1. Install the No. 1 transmission clutch hub onto the output shaft.

    NOTICE:
    Align the cutout of the No. 1 transmission clutch hub with the protrusion of the No. 1 synchronizer ring as shown in the illustration.



7. INSTALL NO. 1 SYNCHROMESH SHIFTING KEY


    C194363

  1. Install the 3 No. 1 synchromesh shifting keys to the No. 1 transmission clutch hub.



8. INSTALL REVERSE GEAR

  1. Coat the reverse gear and No. 1 transmission clutch hub with gear oil.



    C194388E01

  1. Install the reverse gear onto the No. 1 transmission clutch hub assembly.

    NOTICE:
    Install the reverse gear as shown in the illustration.



9. INSTALL NO. 1 SYNCHRONIZER RING SET (FOR 2ND GEAR)

  1. Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.



    C194389

  1. Install the outer ring onto the No. 1 transmission clutch hub.

    NOTICE:
    Align the protrusion of the outer ring with the cutout of the No. 1 transmission clutch hub before installing the outer ring.



    C194390

  1. Install the middle ring onto the outer ring.



    C194391E02

  1. Install the inner ring onto the middle ring.
    Text in Illustration 
    *1
    		Cutout
    *2
    		Middle Ring
    *3
    		Outer Ring

    NOTICE:
    Align the cutout of the outer ring with the protrusion of the inner ring before installing the inner ring.



10. INSTALL INNER 2ND GEAR BEARING RACE


    C194360E01

  1. Coat the inner 2nd gear bearing race with gear oil and install it onto the output shaft.



11. INSTALL 2ND GEAR NEEDLE ROLLER BEARING


    C194359E01

  1. Coat the 2nd gear needle roller bearing with gear oil and install it onto the output shaft.



12. INSTALL 2ND GEAR


    C194392E02

  1. Coat the 2nd gear with gear oil and install it onto the output shaft.
    Text in Illustration 
    *1
    		Groove
    *2
    		Claw

    NOTICE:
    Align the claw of the middle ring with the groove of the 2nd gear before installing the 2nd gear.



13. INSTALL 3RD DRIVEN GEAR


    C194393E01

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

    SST
    09316-60011   (09316-00011)



14. INSTALL OUTPUT GEAR SPACER


    C194357E01

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



15. INSTALL 4TH DRIVEN GEAR


    C194394E01

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

    SST
    09309-37010  
    09502-24010  



16. INSTALL 5TH DRIVEN GEAR


    C194395E01

  1. Using SST and a press, install the 5th driven gear onto the output shaft.

    SST
    09316-60011   (09316-00011)



17. INSTALL OUTPUT GEAR SPACER


    C194355E01

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



18. INSTALL 6TH DRIVEN GEAR


    C194396E01

  1. Using SST and a press, install the 6th driven gear onto the output shaft.

    SST
    09226-10010  



19. INSTALL REAR OUTPUT SHAFT BEARING


    C194397E01

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

    SST
    09608-04031  



20. INSPECT 2ND GEAR RADIAL CLEARANCE


    C194353

  1. Using a dial indicator, measure the 2nd gear radial clearance.

    Standard clearance:
    0.009 to 0.077 mm (0.000354 to 0.00303 in.)

    Maximum clearance:
    0.077 mm (0.00303 in.)

    If the clearance exceeds the maximum, replace the 2nd gear, 2nd gear needle roller bearing or output shaft.



21. INSPECT 1ST GEAR RADIAL CLEARANCE


    C194352

  1. Using a dial indicator, measure the 1st gear radial clearance.

    Standard clearance:
    0.009 to 0.077 mm (0.000354 to 0.00303 in.)

    Maximum clearance:
    0.077 mm (0.00303 in.)

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



22. INSPECT 2ND GEAR THRUST CLEARANCE


    C194351

  1. Using a dial indicator, measure the 2nd gear thrust clearance.

    Standard clearance:
    0.15 to 0.33 mm (0.00591 to 0.0130 in.)

    Maximum clearance:
    0.33 mm (0.0130 in.)

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



23. INSPECT 1ST GEAR THRUST CLEARANCE


    C194350

  1. Using a dial indicator, measure the 1st gear thrust clearance.

    Standard clearance:
    0.20 to 0.38 mm (0.00787 to 0.0150 in.)

    Maximum clearance:
    0.38 mm (0.0150 in.)

    If the clearance exceeds the maximum, replace the No. 1 transmission clutch hub, 1st gear bush or 1st gear.