Reassembly

R155 MANUAL TRANSMISSION: OUTPUT SHAFT: REASSEMBLY

1. INSTALL NO. 2 TRANSMISSION HUB SLEEVE





(a) Install the 3 synchromesh shifting key springs No. 2 and the 3 synchro-mesh shifting key No. 2 to the transmission clutch hub No. 2.

NOTICE:
Make sure that the transmission hub sleeve No. 2 and transmission clutch hub No. 2 are oriented in the correct direction.

(b) Apply gear oil to the sliding part of the transmission hub sleeve No. 2, and install it onto the transmission clutch hub No. 2.

2. INSTALL 3RD GEAR NEEDLE ROLLER BEARING





(a) Apply gear oil to the 3rd gear needle roller bearing, and install it onto the output shaft.

3. INSTALL 3RD GEAR





(a) Apply gear oil to the 3rd gear, and install it onto the output shaft.

4. INSTALL NO. 2 SYNCHRONIZER RING





(a) Apply gear oil to the synchronizer ring No. 2, and install it onto the 3rd gear.

5. INSTALL NO. 2 TRANSMISSION CLUTCH HUB





(a) Using SST, install the transmission clutch hub No. 2 onto the output shaft.

SST : 09608-06041

NOTICE:
* Install it with the synchronizer ring key No. 2 groove aligned with the shifting key position.
* Make sure that the 3rd gear rotates smoothly.
(b) Select the correct clutch hub shaft snap ring so that the clearance between the transmission clutch hub No. 2 and shaft snap ring thrust is within the specified values. Then install it onto the output shaft.





Standard clearance:

0.1 mm or less

NOTICE:
Do not damage the sliding surface of the bearing.





6. INSTALL 2ND GEAR NEEDLE ROLLER BEARING





(a) Apply gear oil to the 2nd gear needle roller bearing, and install it onto the output shaft.

7. INSTALL 2ND GEAR





(a) Apply gear oil to the 2nd gear, and install it onto the output shaft.

8. INSTALL NO. 1 SYNCHRONIZER RING SET





(a) Apply gear oil to the synchronizer ring set No. 1, and install it onto the 2nd gear.

9. INSTALL REVERSE GEAR





(a) Using a screwdriver, install the 3 synchromesh shifting key springs and 3 synchromesh shifting key No.1 onto the transmission clutch hub No. 1.

(b) Apply gear oil to the revers gear, and install it onto the transmission clutch hub No. 1

10. INSTALL NO. 1 TRANSMISSION CLUTCH HUB





(a) Using SST and a press, install transmission clutch hub No. 1 onto the output shaft.

SST : 09316-60011

09316-00041

NOTICE:
* Perform installation making sure that the synchronizer ring key No. 1 groove and synchro-mesh shifting key No. 1 are in place.
* Make sure that the 1st gear rotates smoothly.
(b) Select the correct bearing shaft snap ring so that the clearance between the transmission clutch hub No. 1 and bearing shaft snap ring is within the specified values. Then install it onto the output shaft.





Standard clearance:

0.1mm (0.039 in.) or less

NOTICE:
Do not damage the sliding surface of the bearing.





11. INSTALL 1ST GEAR BEARING SPACER





(a) Apply gear oil to the 1st gear bearing spacer, and install it onto the output shaft.

12. INSTALL 1ST GEAR NEEDLE ROLLER BEARING





(a) Apply gear oil to the 1st gear needle roller bearing, and install it onto the output shaft.

13. INSTALL 1ST GEAR THRUST WASHER PIN OR BALL





(a) Install the 1st gear thrust washer pin onto the output shaft.

14. INSTALL NO. 1 SYNCHRONIZER RING





(a) Apply gear oil to the synchronizer ring No. 1, and install it onto the output shaft.

15. INSTALL 1ST GEAR





(a) Apply gear oil to the 1st gear, and install it onto the output shaft.

16. INSTALL 1ST GEAR THRUST WASHER





(a) Apply gear oil to the 1st gear thrust washer, and install it onto the output shaft.

17. INSTALL OUTPUT SHAFT CENTER BEARING





(a) Using SST and a press, install a new output shaft center bearing onto the output shaft.

SST : 09316-60011

09316-00031

NOTICE:
Install it with the snap ring groove of the bearing facing to the rear side.

18. INSTALL 5TH GEAR





(a) Using SST and a press, install the 5th gear onto the output shaft.

SST : 09316-60011

09316-00031

NOTICE:
* Check that the 5th gear is fitted into the spline of the output shaft before installing.
* Face the convex part of the gear to the front side.
19. INSPECT 1ST GEAR THRUST CLEARANCE





(a) Using a dial indicator, measure the 1st gear thrust clearance.

Standard clearance:

0.20 to 0.45 mm (0.0079 to 0.0177 in.)

20. INSPECT 2ND GEAR THRUST CLEARANCE





(a) Using a dial indicator, measure the 2nd gear thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.0039 to 0.0098 in.)

21. INSPECT 3RD GEAR THRUST CLEARANCE





(a) Using a feeler gauge, measure the 3rd gear thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.0039 to 0.0098 in.)

22. INSPECT 1ST GEAR RADIAL CLEARANCE





(a) Using a dial indicator, measure the 1st gear radial clearance.

Standard clearance:

0.020 to 0.073 mm (0.0008 to 0.0029 in)

(b) If the clearance is not within the specified values, replace the 1st gear needle roller bearing with a new one.

23. INSPECT 2ND GEAR RADIAL CLEARANCE





(a) Using a dial indicator, measure the 2nd gear radial clearance.

Standard clearance:

0.015 to 0.068 mm (0.0006 to 0.0027 in.)

(b) If the clearance is not within the specified values, replace the 2nd gear needle roller bearing with a new one.

24. INSPECT 3RD GEAR RADIAL CLEARANCE





(a) Using a dial indicator, measure the 3rd gear radial clearance.

Standard clearance:

0.015 to 0.068 mm (0.0006 to 0.0027 in.)

(b) If the clearance is not within the specified values, replace the 3rd gear needle roller bearing with a new one.