Output Shaft Assembly
OUTPUT SHAFT ASSEMBLYHINT: 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 3 springs and shifting keys to the clutch hub.
b. Install the hub sleeve to the clutch hub.
HINT: Position the identification groove of the hub sleeve to the front of the transmission.
2. INSTALL THRUST WASHER, 1ST GEAR, NEEDLE ROLLER BEARING, SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO OUTPUT SHAFT
a. Using SST and a press, install the thrust washer.
SST 09316-60011 (09316-00041)
b. Apply gear oil to the needle roller bearing.
c. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
d. Using a press, install the 1st gear and No.1 hub sleeve.
3. INSPECT 1ST GEAR THRUST CLEARANCE
4. INSTALL SYNCHRONIZER RING, 2 ND GEAR, NEEDLE ROLLER BEARING AND 3RD DRIVEN GEAR
a. Install the ball.
b. Fit the 2nd gear bushing groove securely over the ball when installing the 2nd gear bushing on the shaft.
c. Place the synchronizer rings on the 2nd gear.
d. Apply gear oil to the needle roller bearing and install it.:
e. Install the 2nd gear.
NOTE: Align the clutch hub grooves with the projections on the synchronizer ring.
f. Using SST and a press, install the 3rd driven gear.
SST 09316-60011 (09316-00011)
5. INSPECT 2ND GEAR THRUST CLEARANCE
6. INSTALL OUTPUT GEAR SPACER, 4TH DRIVEN GEAR AND RADIAL BALL BEARING
a. Install the outer gear spacer.
b. Using a press. install the 4th driven gear and bearing.
7. INSTALL REAR BEARING
Using SST and a press. install the rear bearing.
SST 09612-22011