Assembly of 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 No.1 clutch hub and shifting keys to the No.1 hub sleeve.
b. Install the shifting key springs under the shifting keys.
NOTE: Position the key springs s0 that their end gaps are not in line.
2. INSTALL BALL. THRUST WASHER, 1ST GEAR, NEEDLE ROLLER BEARING. SYNCHRONIZER RING AND NO.1 HUB SLEEVE ASSEMBLY TO OUTPUT SHAFT
a. Install the ball to 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
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
7. INSTALL OUTPUT GEAR SPACER. 4TH DRIVEN GEAR AND REAR BALL BEARING
a. Install the output gear spacer.
b. Using SST and a press, install the 4th driven gear and rear ball bearing.
SST 09608-00071