Assembly of Output Shaft Assembly

1. INSERT NO.1 AND NO.2 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 THIRD GEAR AND NO.2 HUB SLEEVE 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 No.2 hub sleeve.




3. INSTALL SNAP RING




a. Select a snap ring that will allow minimum axial play.




b. Using snap ring pliers, install the snap ring.




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.)

5. INSTALL SECOND GEAR AND NO.1 HUB SLEEVE




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 No.1 hub sleeve.




6. INSTALL SNAP RING




a. Select a snap ring that will allow minimum axial play.




b. Using a screwdriver and hammer, install the snap ring.
7. INSTALL SPACER AND FIRST GEAR ASSEMBLY




a. Install the spacer on the output shaft.




b. Apply gear oil to the needle roller bearing.
c. Assemble the 1st gear, synchronizer ring and needle roller bearing.
d. Install the assembly on the output shaft with the synchronizer ring slots aligned with the shifting keys.




8. INSTALL STRAIGHT PIN AND FIRST GEAR THRUST WASHER
Install the 1st gear thrust washer onto the output shaft with the straight pin aligned with the 1st gear thrust washer.




9. INSTALL OUTPUT SHAFT CENTER BEARING
Using SST, drive in the bearing with the outer race snap ring groove toward the rear.
SST 09309-35010




10. MEASURE FIRST GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 1st gear thrust clearance.

Standard clearance: 0.10 - 0.45 mm (0.0039 - 0.0177 in.)




11. MEASURE SECOND GEAR THRUST CLEARANCE
Using a dial indicator, measure the 2nd gear thrust clearance.

Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098in.)




12. INSTALL FIFTH GEAR
Using SST and a press, install the 5th gear.
SST 09316-60010 (09316-00030)