Assembly of Output Shaft Assembly

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




1. INSERT 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 end gaps are not in line.




2. INSTALL THRUST WASHER, 1ST GEAR, NEEDLE ROLLER BEARING, SYNCHRONIZER RING AND NO. 1 HUB SLEEVE TO OUTPUT SHAFT
a. Install the locking ball in the shaft.
b. Fit the thrust washer groove securely over the locking ball when installing the thrust on the shaft.
c. Apply gear oil to the needle roller bearing.




d. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.




e. Using a press install the 1st gear and No.1 hub sleeve.







3. INSTALL SNAP RING
a. Select a snap ring that will allow minimum axial play.




b. Using a screwdriver and hammer, tap in the snap ring.




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

Standard clearance: 0.10 - 0.40 mm (0.0039 - 0.0157 in.)




5. INSTALL SYNCHRONIZER RING, 2ND GEAR, NEEDLE ROLLER BEARING AND 3RD DRIVEN GEAR
a. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
b. Apply gear oil to the needle roller bearing.
c. Install the 2nd gear.




d. Using a press, install the 3rd driven gear.




6. INSPECT 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 OUTPUT GEAR SPACER, 4TH DRIVEN GEAR AND RADIAL BALL BEARING
a. Install the output gear spacer.
b. Using SST and a press, install the 4th driven gear and bearing.
SST 09608-12010 (09608-00070)