Assembly

ASSEMBLY OF OUTPUT SHAFT ASSEMBLY
1. INSERT CLUTCH HUB NO.1 AND NO.2 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.
NOTICE: Install the key springs positioned so that their end gaps are not in line.





2. INSTALL THIRD GEAR AND HUB SLEEVE NO.2 ON OUTPUT SHAFT
(a) Apply gear oil to the shaft and needle roller bearing.
(b) Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
(c) Install the needle roller bearing in the 3rd gear.





(d) Using a press, install the 3rd gear and hub sleeve No.2.








3. INSTALL SNAP RING
Select a snap ring that will allow minimum axial, play and install it on the shift.





4. MEASURE THIRD GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 3rd gear thrust clearance.
Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 in.)
Maximum clearance:
0.25 mm (0.0098 in.)





5. INSTALL SECOND GEAR AND HUB SLEEVE NO.1
(a) Apply gear oil to the shaft and needle roller bearing.
(b) Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
(c) Install the needle roller bearing in the 2nd gear.





(d) Using a press, install the 2nd gear and hub sleeve No.1.





6. MEASURE SECOND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 2nd gear thrust clearance.
Standard clearance:
0.10 - 0.25 mm (0.0039 0.0098 in.)
Maximum clearance:
0.25 mm (0.0098 in.)





7. INSTALL LOCKING BALL AND FIRST GEAR ASSEMBLY
(a) Install the locking ball in the shaft.





(b) Apply gear oil to the needle roller bearing.
(c) Assemble the 1st gear, synchronizer ring, needle roller bearing and bearing inner race.
(d) Install the assembly on the output shaft with the synchronizer ring slots aligned with the shifting keys.
(e) Turn the inner race to align it with the locking ball.





8. INSTALL OUTPUT SHAFT REAR BEARING
Using SST and a press, install the bearing on the output shaft with the outer race snap ring groove toward the rear.
HINT: Hold the 1st gear inner race to prevent it from falling.
SST 09506-35010





9. (5-Speed)
INSTALL FIFTH GEAR
Using SST and a press, install the 5th gear.
SST 09506-35010








10. 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.





11. MEASURE FIRST GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 1st gear thrust clearance.
Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 in.)
Maximum clearance:
0.25 mm (0.0098 in.)





12.-1 (2WD)
INSTALL SPEEDOMETER DRIVE GEAR
(a) Using snap ring pliers, install the snap ring.
(b) Install the ball and drive gear.
(c) Using snap ring pliers, install the snap ring.





12.-2 (4WD)
INSTALL SLEEVE TO OUTPUT SHAFT
Using a plastic hammer, tap the sleeve onto the output shaft.