Assembly of Output Shaft Assembly

ASSEMBLY OF OUTPUT SHAFT ASSEMBLY

NOTE: Coat all 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.

CAUTION: Install the key springs positioned so that their end gaps are not in line.




2. INSTALL NEEDLE ROLLER BEARINGS, 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.




d. Using SST and a press, install the 1st gear and No.1 hub sleeve.
SST 09316-60010 (09316-00040)




3. 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.)




4. INSTALL BALL, SECOND GEAR BUSHING, NEEDLE ROLLER BEARING
a. Install the ball and bushing.
b. Apply MP grease to the needle roller bearing.
c. Install the needle roller bearing.




5. SYNCHRONIZER RING, SECOND GEAR AND THIRD DRIVEN GEAR
a. Place the synchronizer ring (for 2nd gear) on the gear and align the ring slots with the shifting keys.
b. Install the 2nd gear.
c. 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 output shaft rear taper roller bearing.
SST 09506-30012