Output Shaft

OUTPUT SHAFT





COMPONENTS

OUTPUT SHAFT (MAIN SHAFT)
DISASSEMBLY





1. Remove a snap ring.





2. Take off a holder and C ring.





3. Pull out a bearing and shim and 6th gear at the same time using a press.

NOTE: Pay attention not to loose a shim between a 6th gear.





4. Pull out spacer.





5. Take off 5th and 4th gear using a press.
6. Take off a shim.





7. Pull out a spacer.





8. Take off the 3rd, the 2nd, the 1st and the reverse gear at the same time using a press.

REASSEMBLY





1. Assemble the reverse gear using special tool (094322C1 00).





2. Assemble a 1st bush using special tool (094322C1 Do).





3. Assemble a needle bearing.





4. Assemble a 1st gear using special tool (094322C1 00).





5. Assemble a synchronizer. The synchronizer ring for 1st gear is double cone type.

NOTE: Pay attention the direction of protrusion of a synchronizer ring.





6. Put 1st/2nd sleeve coupling assembly with projecting side lower.
7. There are 3 grooves near the spline for 1st gear side, and 4 grooves for 2nd side.





8. Put sleeve coupling with projecting side lower, and also pay attention to set a hub notch with coupling notch.
9. Press on coupling assembly using special tool (09432-3A100).

NOTE: Keep under side 3 grooves of a hub.





10. Pay attention the protrusion of synchronizer ring is engaged with hub notch.





11. Assemble a 2nd bush using special tool (09432-3A100).

NOTE: Pay attention to the bush's inclining.





12. Assemble a synchronizer ring and needle bearing on output shaft.





13. Assemble a 2nd gear on the output shaft.





14. Assemble 3rd gear using special tool (09432-3A100).

NOTE: Pay attention as a groove direction keeps upper.





15. Select the correct adjust shim of 4th gear as "L" dimension becomes below basic dimension and assemble it.

NOTE: There are 2 type spacers. One spacer has notches, the other doesn't have notches. In this case, assemble a spacer without notches.

L (mm): 173.85 - 173.95








4TH GEAR ADJUST SHIM

16. Press on 4th gear using special tool (09432-3A100).

NOTE: Pay attention as a groove direction keeps upper.

17. Press on 5th gear using special tool (09432-3A100).

NOTE: Pay attention as a groove direction keeps upper.

18. Assemble 5th spacer.





19. Press on 6th gear.

NOTE: Pay attention as a groove direction keeps upper.

20. Select the correct adjust shim of 6th gear to minimize clearance between 6th gear and input shaft spline edge, and then assemble it.
L (mm): 0 - 0.1








6TH OUTPUT ADJUST SHIM





21. Press on output shaft rear bearing using special tool (09432-22000).

NOTE: Pay attention as a groove direction keeps upper. Select the correct 2 C-rings of output shaft bearing to minimize clearance of groove in output shaft and then assemble them.

22. Select the correct 2 C-rings of output shaft bearing to minimize clearance of groove in output shaft and then assemble them.
L (mm): 0 - 0.06

OUTPUT SHAFT BEARING C RING





23. Assemble a holder and a snap ring.