Output Shaft Assembly

HINT: Coat all of the sliding and rotating surfaces with gear oil before assembly.




1. INSTALL NO.1 CLUTCH HUB INTO HUB SLEEVE
a. Install the clutch hub and shifting keys to the hub sleeve.
b. Install the shifting key springs under the shifting keys.

NOTE: Install the key springs positioned so that their ends are not in line.




2. INSTALL NEEDLE ROLLER BEARING, 1ST GEAR, SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO OUTPUT SHAFT
a. Apply MP grease to the needle roller bearing.
b. Install the 1st gear.
c. Place the synchronizer ring (for 1st gear) on the gear and align the ring slots with the shifting keys.




d. Using SST and a press, install the 1st gear and No.1 hub sleeve.
SST 09316-60010 (09316-00040)




3. INSTALL SNAP RING




a. Select a snap ring that will allow minimum axial play.




b. Using a snap ring expander, install the snap ring.




4. MEASURE 1ST GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 1st gear thrust clearance.

Standard clearance: 0.10 - 0.35 mm (0.0039 - 0.0138 in.)




5. INSTALL SPACER, NEEDLE ROLLER BEARING, SYNCHRONIZER RINGS, 2ND GEAR AND 3RD DRIVEN GEAR
a. Install the spacer.
b. Apply MP grease to the needle roller bearing.
c. Place the synchronizer rings (for 2nd gear) on the gear.

NOTE: Do not install the synchronizer ring for the 1st gear.




d. Install the 2nd gear.
e. Using a press, install the 3rd driven gear.

NOTE: Align the clutch hub grooves with the projections on the synchronizer ring.




6. MEASURE 2ND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 2nd gear thrust clearance.

Standard clearance: 0.10 - 0.45 mm (0.0039 - 0.0177 in.)




7. INSTALL SPACER AND 4TH DRIVEN GEAR
a. Install the spacer.
b. Using a press, install the 4th driven gear.




8. INSTALL OUTPUT SHAFT REAR BEARING
Using SST and a press, install the bearing.
SST 09506-30012




9. INSTALL OUTPUT SHAFT FRONT BEARING
Using SST and a press, install a new output shaft front bearing.
SST 09316-60010 (09316-00070)