EC60 MANUAL TRANSMISSION / TRANSAXLE  OUTPUT SHAFT  REASSEMBLY  


PROCEDURE

Hide 33321N 1.INSTALL FRONT OUTPUT SHAFT BEARING

a.
C304164
2.948,1.927 2.365,1.927 2.365,1.927 2.365,1.625 false 2.948,2.094 2.948,1.625 false 2.354,0.635 2.49,0.635 false 0.896,2.427 0.688,1.729 0.688,1.729 1.01,1.729 false 0.385,1.646 0.844,1.844 0.458,0.198 10 false SST 2.833,2.125 3.292,2.323 0.458,0.198 10 false SST 2.073,0.563 2.531,0.76 0.458,0.198 10 false SST

Using SST and a press, install a new front output shaft bearing (inner race) to the output shaft.

SST
09309-14040  
09612-22011  


Hide 33345 2.INSTALL 1ST GEAR BUSHING

a.
C194368

Coat the 1st gear bushing with gear oil and install it to the output shaft.


Hide 33335C 3.INSTALL 1ST GEAR NEEDLE ROLLER BEARING

a.
C194367

Coat the 1st gear needle roller bearing with gear oil and install it to the output shaft.


Hide 33335 4.INSTALL 1ST GEAR

a.
A295609

Coat the 1st gear with gear oil and install it to the output shaft.

NOTICE:

Install the 1st gear as shown in the illustration.



Hide 33037B 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.
C194386

Install the inner ring to the 1st gear.


c.

Install the middle ring to the 1st gear.

NOTICE:

Engage the claws of the middle ring to the grooves of the 1st gear.



d.

Install the outer ring to the 1st gear.

NOTICE:

Align the claws of the inner ring with the grooves of the outer ring before installing the outer ring.



Hide 33361 6.INSTALL NO. 1 TRANSMISSION CLUTCH HUB

a.
C194387

Install the No. 1 transmission clutch hub to the output shaft.

NOTICE:

Align the cutouts of the No. 1 transmission clutch hub with the protrusions of the outer ring as shown in the illustration.



Hide 33365 7.INSTALL NO. 1 SYNCHROMESH SHIFTING KEY

a.
C194363

Install the 3 No. 1 synchromesh shifting keys to the No. 1 transmission clutch hub.


Hide 33331 8.INSTALL REVERSE GEAR

a.

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


b.
A295610

Install the reverse gear to the No. 1 transmission clutch hub.

NOTICE:

Install the reverse gear as shown in the illustration.



Hide 33037B 9.INSTALL NO. 1 SYNCHRONIZER RING SET (for 2nd Gear)

a.

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


b.
A295611

Install the outer ring to the No. 1 transmission clutch hub.

NOTICE:

Align the protrusion of the outer ring with the cutout of the No. 1 transmission clutch hub before installing the outer ring.



c.
C194390

Install the middle ring to the outer ring.


d.
C194391
2.469,0.448 3.042,0.396 3.042,0.396 2.948,1.156 false 2.094,1.24 3.021,0.427 false 0.958,1.844 1.458,2.646 1.458,2.646 1.979,2.646 true 0.771,2.448 1.563,3.177 1.563,3.177 1.917,3.177 true 3.063,0.219 3.281,0.469 0.219,0.25 10 false *c 1.979,3.073 2.219,3.281 0.24,0.208 10 false *b 2.063,2.563 2.823,2.781 0.76,0.219 10 false *a
*a Inner Ring
*b Outer Ring
*c Cutout


Install the inner ring to the middle ring.

NOTICE:

Align the cutouts of the outer ring with the protrusions of the inner ring before installing the inner ring.



Hide 33356A 10.INSTALL INNER 2ND GEAR BEARING RACE

a.
A295606

Coat the inner 2nd gear bearing race with gear oil and install it to the output shaft.


Hide 33332B 11.INSTALL 2ND GEAR NEEDLE ROLLER BEARING

a.
A295385

Coat the 2nd gear needle roller bearing with gear oil and install it to the output shaft.


Hide 33332 12.INSTALL 2ND GEAR

a.
C194392
0.688,1.385 0.74,1.229 0.74,1.229 1.521,1.229 true 0.698,0.781 0.51,1.146 0.51,1.146 0.375,1.146 true 0.167,1.063 0.698,1.292 0.531,0.229 10 false *b 1.563,1.146 1.938,1.344 0.375,0.198 10 false *a
*a Claw
*b Groove


Coat the 2nd gear with gear oil and install it to the output shaft.

NOTICE:

Align the claws of the middle ring with the grooves of the 2nd gear before installing the 2nd gear.



Hide 33423A 13.INSTALL 3RD DRIVEN GEAR

a.
C194393
0.677,1.458 0.406,1.458 false 2.427,0.625 2.229,0.625 false 0.073,1.385 0.365,1.552 0.292,0.167 10 SST 1.896,0.552 2.208,0.76 0.313,0.208 10 SST

Using SST and a press, install the 3rd driven gear to the output shaft.

SST
09316-60011  (09316-00011)


Hide 33431C 14.INSTALL OUTPUT GEAR SPACER

a.
A295607

Install the output gear spacer to the output shaft.


Hide 33422B 15.INSTALL 4TH DRIVEN GEAR

a.
C194394
0.792,1.094 0.417,1.094 0.417,1.094 0.688,1.365 false 2.313,1.479 2.031,1.479 2.031,1.479 2.031,2.021 false 2.917,1.792 3.115,1.792 3.115,1.792 3.115,2.031 false 0.073,1.031 0.406,1.26 0.333,0.229 10 SST 1.896,2.073 2.229,2.302 0.333,0.229 10 SST 2.979,2.073 3.281,2.302 0.302,0.229 10 SST

Using SST and a press, install the 4th driven gear to the output shaft.

SST
09309-37010  
09502-24010  


Hide 33428C 16.INSTALL 5TH DRIVEN GEAR

a.
C194395
0.823,1.333 0.531,1.333 false 2.333,1.271 2.063,1.271 2.063,1.271 2.063,1.458 false 0.25,1.271 0.583,1.49 0.333,0.219 10 SST 1.927,1.521 2.26,1.74 0.333,0.219 10 SST

Using SST and a press, install the 5th driven gear to the output shaft.

SST
09316-60011  (09316-00011)


Hide 33431C 17.INSTALL OUTPUT GEAR SPACER

a.
A295384

Install the output gear spacer to the output shaft.


Hide 33429B 18.INSTALL 6TH DRIVEN GEAR

a.
C194396
0.823,0.865 0.563,0.865 false 2.458,0.552 2.302,0.552 false 0.25,0.792 0.698,1.052 0.448,0.26 10 false SST 2,0.49 2.448,0.75 0.448,0.26 10 false SST

Using SST and a press, install the 6th driven gear to the output shaft.

SST
09226-10010  


Hide 33321A 19.INSTALL REAR OUTPUT SHAFT BEARING

a.
C194397
0.885,0.938 0.563,0.938 false 2.427,0.688 2.083,0.688 2.083,0.688 2.083,1.052 false 0.26,0.875 0.594,1.063 0.333,0.188 10 SST 1.948,1.094 2.281,1.281 0.333,0.188 10 SST

Using SST and a press, install a new rear output shaft bearing to the output shaft.

SST
09608-04031  


Hide 20.INSPECT 2ND GEAR RADIAL CLEARANCE

Hide 21.INSPECT 1ST GEAR RADIAL CLEARANCE

Hide 22.INSPECT 2ND GEAR THRUST CLEARANCE

Hide 23.INSPECT 1ST GEAR THRUST CLEARANCE