Installation

E350 MANUAL TRANSAXLE: OUTPUT SHAFT: INSTALLATION

INSTALLATION





1. INSTALL REVERSE GEAR
(a) Coat the reverse gear with gear oil.
(b) Install the 3 No. 1 synchromesh shifting key springs and No. 1 transmission clutch hub to the reverse gear.
NOTE: Assemble the reverse gear and the No. 1 transmission clutch hub in the correct direction.

(c) Using a screwdriver, install the 3 No. 1 synchromesh shifting keys to the reverse gear.






2. INSTALL FRONT OUTPUT SHAFT BEARING
(a) Using SST and a press, press in the front bearing (inner race) to the output shaft.
SST: 09950-60010
09951-00430
SST: 09950-70010
09951-07150






3. INSTALL NO. 1 SYNCHRONIZER RING SET
(a) Coat the No. 1 synchronizer ring set with gear oil, and install it to the 1st gear.
NOTE: Align the claw of the No. 1 synchronizer ring set (middle) with the hole of the 1st gear and install it.





4. INSTALL 1ST GEAR NEEDLE ROLLER BEARING
(a) Coat the needle roller bearing with gear oil, and install it to the output shaft.






5. INSTALL 1ST GEAR
(a) Coat the 1st gear with gear oil, and install it to the output shaft.






6. INSTALL NO. 1 TRANSMISSION CLUTCH HUB
(a) Using SST and a press, press in the No. 1 transmission clutch hub to the output shaft.
SST: 09316-60011
09316-00031
SST: 09950-60010
09951-00320
SST: 09950-70010
09951-07100
NOTICE:
- Align the claw of the No. 1 synchronizer ring set (outer) with the hole of the No. 1 transmission clutch hub and install it.
- Make sure that the 1st gear rotates.





7. INSTALL 2ND GEAR BUSH BALL
(a) Coat the bush ball with MP grease, and install it to the output shaft.






8. INSTALL 2ND GEAR BUSH
(a) Coat the bush with gear oil, and install it to the output shaft.






9. INSTALL 2ND GEAR BEARING SPACER
(a) Coat the bearing spacer with gear oil, and install it to the output shaft.






10. INSTALL 2ND GEAR NEEDLE ROLLER BEARING
(a) Coat the needle roller bearing with gear oil, and install it to the output shaft.






11. INSTALL NO. 2 SYNCHRONIZER RING SET
(a) Coat the No. 2 synchronizer ring set with gear oil, and install it to the No. 1 transmission clutch hub.
NOTE: Align the key groove on the No. 2 synchronizer ring set with the No. 1 synchromesh shifting key.





12. INSTALL 2ND GEAR
(a) Coat the 2nd gear with gear oil, and install it to the output shaft.






13. INSTALL 3RD DRIVEN GEAR
(a) Using SST and a press, press in the 3rd driven gear to the output shaft.
SST: 09608-00071
SST: 09950-60010
09951-00320
SST: 09950-70010
09951-07100






14. INSTALL OUTPUT GEAR SPACER
(a) Install the output gear spacer to the output shaft.






15. INSTALL 4TH DRIVEN GEAR
(a) Using SST and a press, press in the 4th driven gear to the output shaft.
SST: 09608-00071
SST: 09950-60010
09951-00320
SST: 09950-70010
09951-07100






16. INSTALL FRONT OUTPUT SHAFT BEARING
(a) Using SST and a press, press in the front bearing (inner race) to the output shaft.
SST: 09506-30012
SST: 09950-60010
09951-00320
SST: 09950-70010
09951-07100






17. INSPECT 2ND GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the radial clearance.
Standard clearance:





If the clearance is out of specification, replace the 2nd gear, 2nd gear bush and 2nd gear needle roller bearing.






18. INSPECT 1ST GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the radial clearance.
Standard clearance:





If the clearance is out of specification, replace the 1st gear and 1st gear needle roller bearing.






19. INSPECT 2ND GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the thrust clearance.
Standard clearance:
0.10 to 0.35 mm (0.0039 to 0.0138 in.)
If the clearance is out of specification, replace the No. 1 transmission clutch hub, 2nd gear or 3rd driven gear.






20. INSPECT 1ST GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the thrust clearance.
Standard clearance:
0.25 to 0.40 mm (0.0098 to 0.0157 in.)
If the clearance is out of specification, replace the 1st gear or No. 1 transmission clutch hub.