Reassembly

C59 MANUAL TRANSAXLE: OUTPUT SHAFT: REASSEMBLY

REASSEMBLY

1. INSPECT OUTPUT SHAFT (Output Shaft)

2. INSPECT 2ND GEAR (Output Shaft)

3. INSPECT 1ST GEAR (Output Shaft)

4. INSPECT 1ST GEAR THRUST WASHER (Output Shaft)

5. INSPECT SYNCHRONIZER RING SET NO. 2 (Output Shaft)

6. INSPECT SYNCHRONIZER RING NO.1 (Output Shaft)

7. INSPECT REVERSE GEAR (Output Shaft)

8. INSPECT TRANSMISSION CLUTCH HUB NO. 1 (Output Shaft)

9. INSTALL REVERSE GEAR





(a) Coat the reverse gear with gear oil, install it to the transmission clutch hub No. 1.

NOTE: Be sure to set the reverse gear and transmission clutch hub No. 1 in incorrect orientation.

(b) Using a screwdriver, install the 3 synchromesh shifting key springs and 3 synchromesh shifting keys.
10. INSTALL OUTPUT SHAFT FRONT BEARING





(a) Using SST and a press, install the new output shaft front bearing (inner race) to the output shaft.
SST: 09223-50010





(b) Select a snap ring from the table below that will make the thrust clearance of the output shaft front bearing (inner race) below 0.1 mm (0.004 in.).





(c) Using a brass bar and a hammer, tap in the snap ring.

NOTE: Take care not to damage the journal surface of the output shaft.

11. INSTALL 1ST GEAR THRUST WASHER PIN OR BALL





(a) Coat the 1st gear thrust washer pin or ball with MP grease, install it to the output shaft.
12. INSTALL 1ST GEAR THRUST WASHER





(a) Coat the 1st gear thrust washer with gear oil, install it to the output shaft.
13. INSTALL 1ST GEAR NEEDLE ROLLER BEARING





(a) Coat the 1st gear needle roller bearing with gear oil, install it to the output shaft.
14. INSTALL 1ST GEAR





(a) Coat the 1st gear with gear oil, install it to the output shaft.
15. INSTALL SYNCHRONIZER RING NO. 1





(a) Coat the synchronizer ring No. 1 with gear oil, install it to the 1st gear.
16. INSTALL TRANSMISSION CLUTCH HUB NO. 1





(a) Using SST and a press, install the transmission clutch hub No. 1 to the output shaft.
SST: 09316-60011
09316-00031

NOTE: The 1st gear can be turned.





(b) Select a snap ring from the table below that will make the thrust clearance of the transmission clutch hub No. 1 below 0.1 mm (0.0004 in.)





(c) Using a brass bar and a hammer, install the snap ring to the output shaft.

NOTE: Take care not to damage the journal surface of the output shaft.

17. INSTALL 2ND GEAR NEEDLE ROLLER BEARING





(a) Coat the 2nd gear needle roller bearing and 2nd gear bearing spacer with gear oil, install them to the output shaft.
18. INSTALL SYNCHRONIZER RING SET NO. 2





(a) Coat the synchronizer ring set No. 2 with gear oil, install it to the 2nd gear.
19. INSTALL 2ND GEAR





(a) Coat the 2nd gear with gear oil, install it to the output shaft.

NOTE: Fit the synchronizer inner ring claws into the slots in the transmission clutch hub No. 1.

20. INSTALL 3RD DRIVEN GEAR





(a) Using SST and a press, install the 3rd driven gear to the output shaft.
SST: 09309-36100
09309-03610
SST: 09608-00071
SST: 09950-60010
09951-00450
21. INSTALL OUTPUT GEAR SPACER





(a) Install the output gear spacer to the output shaft.
22. INSTALL 4TH DRIVEN GEAR





(a) Using SST and a press, install 4th driven gear to the output shaft.
SST: 09612-22011
23. INSTALL OUTPUT SHAFT REAR BEARING





(a) Using SST and a press, install output shaft rear bearing to the output shaft.
SST: 09612-22011
24. INSPECT 2ND GEAR RADIAL CLEARANCE (Output Shaft)

25. INSPECT 1ST GEAR RADIAL CLEARANCE (Output Shaft)

26. INSPECT 2ND GEAR THRUST CLEARANCE (Output Shaft)

27. INSPECT 1ST GEAR THRUST CLEARANCE (Output Shaft)