Output Shaft: Reassembly

HINT:

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

1. INSTALL NO. 1 AND NO. 2 CLUTCH HUBS INTO HUB SLEEVE 
   1. Install the 3 shifting key springs to the clutch hub.
   2. While pushing the shifting key spring with a screwdriver, install the 3 shifting keys.
      Fig 1: Installing Shifting Keys

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   3. While pushing the 3 shifting keys, install the clutch hub to the hub sleeve, as shown in Fig 2 .
      Fig 2: Installing Clutch Hub To Hub Sleeve

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2. INSTALL 3RD GEAR AND NO. 2 CLUTCH HUB ON OUTPUT SHAFT 
   1. Apply gear oil to the shaft.
   2. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
      Fig 3: Aligning Ring Slots With Shifting Keys

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   3. Using a press, install the 3rd gear and No. 2 clutch hub.
      Fig 4: Installing 3rd Gear & No. 2 Clutch Hub

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3. INSTALL SNAP RING 
   1. Select a snap ring that will allow minimum axial play.
      Fig 5: Installing Snap Ring

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   2. Using a snap ring expander, install the snap ring.
   Fig 6: Snap Ring Thickness Table
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4. INSPECT 3RD GEAR THRUST CLEARANCE (See  DISASSEMBLY  ) 
5. INSTALL 2ND GEAR AND NO. 1 CLUTCH HUB 
   1. Apply gear oil to the shaft and needle roller bearing.
   2. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
   3. Install the needle roller bearing in the 2nd gear.
      Fig 7: Aligning Ring Slots With Shifting Key

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   4. Using a press, install the 2nd gear and No. 1 clutch hub.
   Fig 8: Installing 2nd Gear & No. 1 Clutch Hub

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6. INSPECT 2ND GEAR THRUST CLEARANCE (See  DISASSEMBLY  ) 
7. INSTALL LOCKING BALL AND 1ST GEAR ASSEMBLY 
   1. Install the locking ball in the shaft.
   2. Apply gear oil to the bearing.
   3. Assemble the 1st gear, synchronizer ring, needle roller bearing and bearing inner race.
   4. Install the assembly on the output shaft with the synchronizer ring slots aligned with the shifting keys and turn the inner race to align it with the locking ball.
   Fig 9: Aligning Synchronizer Ring Slots With Shifting Keys

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8. INSTALL OUTPUT SHAFT CENTER BEARING 

   Using SST and a press, install the center bearing on the output shaft with the outer race snap ring groove toward the rear.

   HINT:

   Hold the 1st gear inner race to prevent it from falling.

   1. SST 09506-35010
9. INSPECT 1ST GEAR THRUST CLEARANCE (See  DISASSEMBLY  ) 
   Fig 10: Installing Output Shaft Center Bearing

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