Assembly of Output Shaft Assembly
ASSEMBLY OF OUTPUT SHAFT ASSEMBLYHINT: 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 NEEDLE ROLLER BEARING, FIRST GEAR, SYNCHRONIZER RING AND NO.1 HUB SLEEVE TO OUTPUT SHAFT
a. Apply MP grease to the needle roller bearings.
b. Install the 1st gear.
c. Place the synchronizer ring (for 1st gear) on the gear and align the ring slots with the shifting keys.
NOTE: Do not install the synchronizer ring for 2nd gear.
d. Using SST and a press, install the 1st gear and No.1 hub sleeve.
SST 09316-60010 (09316-00040)
3. INSTALL SNAP RING
Select a snap ring that will allow minimum axial play and install it on the shaft.
4. MEASURE FIRST GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 1st gear thrust clearance.
Standard clearance: 0.10 - 0.35 mm (0.0039 - 0.0138 in.)
5. INSTALL SPACER. NEEDLE ROLLER BEARING, SYNCHRONIZER RING, SECOND GEAR AND THIRD DRIVEN GEAR
a. Install the spacer.
b. Apply MP grease to the needle roller bearing.
c. Place the synchronizer ring (for 2nd gear) on the gear and align the ring slots with the shifting keys.
NOTE: Do not install the synchronizer ring for 1st gear.
d. Install the 2nd gear.
e. Using a press, install the 3rd driven gear.
6. MEASURE SECOND 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 SPACER AND FOURTH DRIVEN GEAR
a. Install the spacer.
b. Using a press, install the 4th driven gear.
8. INSTALL OUTPUT SHAFT REAR BEARING
Using SST and a press, install the bearing.
SST 09506-30012