Output Shaft

DISASSEMBLY
1. INSPECT EACH GEAR THRUST CLEARANCE





a. Using a feeler gauge, measure the thrust clearance of 1st and 3rd gear.
Standard clearance:
1st gear: 0.20 - 0.45 mm (0.0078 - 0.0177 inch)
3rd gear: 0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Maximum clearance:
1st gear: 0.50 mm (0.0197 inch)
3rd gear: 0.30 mm (0.0118 inch)





b. Using a dial indicator, measure the thrust clearance of 2nd gear.
Standard clearance:
2nd gear: 0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Maximum clearance:
2nd gear: 0.30 mm (0.0118 inch)





2. INSPECT EACH GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance of each gear.
Standard clearance:
1st gear: 0.020 - 0.073 mm (0.0008 - 0.0029 inch)
2nd and 3rd gears: 0.015 - 0.068 mm (0.0006 - 0.0027 inch)
Maximum clearance:
1st gear: 0.160 mm (0.0063 inch)
2nd and 3rd gears: 0.160 mm (0.0063 inch)
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.





3. REMOVE 5TH GEAR, OUTPUT SHAFT CENTER BEARING AND 1ST GEAR ASSEMBLY
a. Using a press, remove the 5th gear, center bearing, thrust washer and 1st gear.
b. Remove the synchronizer inner ring, middle ring and outer ring from the 1st gear.
c. Remove the straight pin and needle roller bearing.
d. Remove the spacer.
4. REMOVE REVERSE GEAR ASSEMBLY AND 2ND GEAR ASSEMBLY





a. Using 2 screwdrivers and a hammer, tap out the snap ring.





b. Using a press, remove the reverse gear assembly and 2nd gear assembly from the output shaft.
c. Remove the needle roller bearing from the output shaft.
d. Remove the synchronizer inner ring, middle ring and outer ring from the 2nd gear.





5. REMOVE REVERSE GEAR, SHIFTING KEY AND SPRING FROM CLUTCH HUB NO. 1
a. Remove the reverse gear from the clutch hub No. 1.
b. Using a screwdriver, push the shifting key spring, remove the 3 shifting keys and key springs from the clutch hub No.1 .
6. REMOVE HUB SLEEVE NO. 2 ASSEMBLY AND 3RD GEAR ASSEMBLY





a. Using a snap ring expander, remove the snap ring.





b. Using a press, remove the hub sleeve No. 2 assembly and 3rd gear assembly from the output shaft.
c. Remove the needle roller bearing from the output shaft.
d. Remove the synchronizer ring from the 3rd gear.
7. REMOVE HUB SLEEVE NO. 2, SHIFTING KEY AND SPRING FROM CLUTCH HUB NO. 2.
a. Remove the hub sleeve No. 2 from the clutch hub No. 2.
b. Using a screwdriver, push the shifting key spring, and remove the 3 shifting keys and 2 key springs from the clutch hub No. 2.

INSPECTION
1. INSPECT OUTPUT SHAFT





a. Using a micrometer, measure the output shaft flange thickness.
Minimum thickness: 4.70 mm (0.1850 inch)
If the thickness is less than the minimum, replace the output shaft.





b. Using a micrometer, measure the outer diameter of the output shaft journal.
Minimum diameter:
A 1st gear: 38.860 mm (1.5299 inch)
B 2nd gear: 46.860 mm (1.8449 inch)
C 3rd gear: 37.860 mm (1.4905 inch)
If the outer diameter is less than the minimum, replace the output shaft.





c. Using a dial indicator, check the shaft runout.
Maximum runout: 0.06 mm (0.0024 inch)
If the runout exceeds the maximum, replace the output shaft.





2. INSPECT 3RD GEAR SYNCHRONIZER RING
a. Check for wear or damage.
b. Check the braking effect of the synchronizer ring.
c. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.

NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.

d. Check again the braking effect of the synchronizer ring.





e. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
Minimum clearance: 0.8 mm (0.031 inch)
If the clearance is less than the minimum, replace the synchronizer ring, and apply a small amount of the fine lapping compound on the gear cone.

NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.

3. INSPECT 1ST AND 2ND GEARS SYNCHRONIZER RING





a. Check for wear or damage.
b. Install the synchronizer inner ring, middle ring and outer ring to each gear.





c. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
If it does not lock, replace the synchronizer ring.





d. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
Minimum clearance: 0.8 mm (0.031 inch)
If the clearance is less than the minimum, replace the synchronizer ring.





4. INSPECT SHIFT FORK AND HUB SLEEVE CLEARANCE
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 inch)
If the clearance exceeds the maximum, replace the shift fork or hub sleeve.

REASSEMBLY

HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.

1. INSTALL CLUTCH HUB NO. 2 INTO HUB SLEEVE NO. 2
a. Install the clutch hub No. 2 and 3 shifting keys to the hub sleeve No. 2.





b. Install the 2 shifting key springs under the shifting keys.

NOTICE: Position the key springs so that their end gaps are not aligned.

2. INSTALL CLUTCH HUB NO. 1 INTO REVERSE GEAR





a. Install the 3 shifting key springs to the clutch hub No. 1.
b. While pushing the shifting key spring with a screwdriver, install the 3 shifting keys.





c. While pushing the 3 shifting keys, install the clutch hub No. 1 to the reverse gear, as shown.
3. INSTALL 3RD 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 assembly and hub sleeve No. 2 assembly.
4. INSTALL SNAP RING








a. Select a snap ring that allows the minimum axial play.
b. Using a snap ring expander, install the snap ring.
5. INSPECT 3RD GEAR THRUST CLEARANCE
6. INSTALL 2ND GEAR AND REVERSE GEAR
a. Apply gear oil to the shaft and needle roller bearing.
b. Place the synchronizer inner ring, middle ring and outer ring on the 2nd gear and align the ring slots with the shifting keys.
c. Align the projection of the synchronizer inner ring with the slots of the clutch hub No. 1. Install the needle roller bearing in the 2nd gear.





e. Using a press, install the 2nd gear assembly and reverse gear assembly.
7. INSTALL SNAP RING








a. Select a snap ring that allows the minimum axial play.





b. Using a snap ring expander, install the snap ring.





8. INSTALL SPACER AND 1ST 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 inner ring, middle ring and outer ring and needle roller bearing.
d. Install the 1st gear assembly on the output shaft with the synchronizer inner ring slots aligned with the shifting keys.





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





10. INSTALL OUTPUT SHAFT CENTER BEARING
Using SST and a hammer, drive in the bearing with the outer race snap ring groove toward the rear.
SST
2WD: 09309-35010
4WD: 09316-60011 (09316-00011, 09316-00071)
11. INSPECT 1ST GEAR THRUST CLEARANCE
12. INSPECT 2ND GEAR THRUST CLEARANCE





13. INSTALL 5TH GEAR
Using SST and a press, install the 5th gear.
SST 09316-60011 (09316-00031)