Reassembly

C59 MANUAL TRANSMISSION / TRANSAXLE: OUTPUT SHAFT: REASSEMBLY

1. INSTALL REVERSE GEAR

(a) Coat the reverse gear and No. 1 transmission clutch hub with gear oil.





(b) Install the 3 synchromesh shifting key springs and 3 synchromesh keys to the No. 1 transmission clutch hub.

(c) Install the reverse gear onto the No. 1 transmission clutch hub assembly.





NOTICE:
Position the reverse gear and No. 1 transmission clutch hub correctly as shown in the illustration.

2. INSTALL 1ST GEAR THRUST WASHER PIN OR BALL

(a) Coat the 1st gear thrust washer pin or ball with MP grease and install it onto the output shaft.





3. INSTALL 1ST GEAR THRUST WASHER

(a) Coat the 1st gear thrust washer with gear oil and install it onto the output shaft.





4. INSTALL 1ST GEAR NEEDLE ROLLER BEARING

(a) Coat the 1st gear needle roller bearing with gear oil and install it onto the output shaft.





5. INSTALL NO. 1 SYNCHRONIZER RING SET (FOR 1ST GEAR)

(a) Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.





(b) Install the inner ring onto the 1st gear.

(c) Install the middle ring onto the 1st gear.





(d) Install the outer ring onto the 1st gear.





6. INSTALL 1ST GEAR

(a) Coat the 1st gear with gear oil and install it onto the output shaft.





7. INSTALL NO. 1 TRANSMISSION CLUTCH HUB

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





SST : 09316-60011

09316-00031

HINT
* Make sure that the 1st gear can be turned.
* While checking that the 1st gear thrust washer pin or ball is inserted into the groove of the 1st gear thrust washer, press and fit the No. 1 clutch hub.

(b) Select a snap ring that will allow minimum axial play.





Standard clearance:

0.1 mm (0.00394 in.) or less

Snap Ring Thickness:





(c) Using a brass bar and a hammer, install the snap ring onto the output shaft.

NOTICE:
Do not damage the output shaft journal surface.

8. INSTALL 2ND GEAR NEEDLE ROLLER BEARING

(a) Coat the 2nd gear needle roller bearing and 2nd gear bearing spacer with gear oil, and install them onto the output shaft.





9. INSTALL NO. 2 SYNCHRONIZER RING SET (FOR 2ND GEAR)

(a) Coat the 2nd gear cone and No. 2 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.





(b) Install the inner ring onto the 2nd gear.

(c) Install the middle ring onto the 2nd gear.





(d) Install the outer ring onto the 2nd gear.





10. INSTALL 2ND GEAR

(a) Coat the 2nd gear with gear oil and install it onto the output shaft.





11. INSTALL 3RD DRIVEN GEAR

(a) Using SST and a press, install the 3rd driven gear onto the output shaft.





SST : 09316-60011

09316-00031

12. INSTALL OUTPUT GEAR SPACER

(a) Install the output gear spacer onto the output shaft.





13. INSTALL 4TH DRIVEN GEAR

(a) Using SST and a press, install the 4th driven gear onto the output shaft.





SST : 09612-22011

14. INSTALL OUTPUT SHAFT REAR BEARING

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





SST : 09612-22011

15. INSPECT 2ND GEAR RADIAL CLEARANCE

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





Standard clearance:

NSK made bearing
0.015 to 0.056 mm (0.000591 to 0.00220 in.)

KOYO made bearing
0.015 to 0.058 mm (0.000591 to 0.00228 in.)

Maximum clearance:

NSK made bearing
0.056 mm (0.00220 in.)

KOYO made bearing
0.058 mm (0.00228 in.)

If the clearance exceeds the maximum, replace the 2nd gear, 2nd gear needle roller bearing or output shaft.

16. INSPECT 1ST GEAR RADIAL CLEARANCE

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





Standard clearance:

NSK made bearing
0.015 to 0.056 mm (0.000591 to 0.00220 in.)

KOYO made bearing
0.015 to 0.058 mm (0.000591 to 0.00228 in.)

Maximum clearance:

NSK made bearing
0.056 mm (0.00220 in.)

KOYO made bearing
0.058 mm (0.00228 in.)

If the clearance exceeds the maximum, replace the 1st gear, 1st gear needle roller bearing or output shaft.

17. INSPECT 2ND GEAR THRUST CLEARANCE

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





Standard clearance:

0.10 to 0.55 mm (0.00394 to 0.0217 in.)

Maximum clearance:

0.55 mm (0.0217 in.)

If the clearance exceeds the maximum, replace the No. 1 transmission clutch hub, 2nd gear or 3rd driven gear.

18. INSPECT 1ST GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the 1st gear thrust clearance.





Standard clearance:

0.10 to 0.40 mm (0.00394 to 0.0157 in.)

Maximum clearance:

0.40 mm (0.0157 in.)

If the clearance exceeds the maximum, replace the 1st gear thrust washer, 1st gear or No. 1 transmission clutch hub.