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                                                                                           MX-35
                     MANUAL TRANSAXLE    -   OUTPUT SHAFT
                                                                                             MX076-03


                                 REASSEMBLY
                                 HINT:
                                 Coat all of the sliding and rotating surfaces with gear oil before
                                 reassembly.
 Engine                          1.    ASSEMBLE REVERSE GEAR ASSEMBLY
 Side
                                 (a) Install the 3 shifting keys and reverse gear to the No. 1
                                       clutch hub.
                                 (b) Install the 2 shifting key springs under the shifting keys.
                        CM0009
                                 NOTICE:
                                 Position the shifting key springs so that their end gaps are
                                 not in line.




                                 2.    INSTALL BALL, THRUST WASHER, NEEDLE ROLLER
                                       BEARING, 1ST GEAR, SYNCHRONIZER RING AND
                                       REVERSE GEAR ASSEMBLY TO OUTPUT SHAFT
                                 (a)   Install the ball to the output shaft.
                                 (b)   Fit the thrust washer groove securely over the locking ball
                                       when installing the thrust on the output shaft.
                                 (c)   Apply gear oil to the needle roller bearing and install it.
                                 (d)   Install the 1st gear and synchronizer ring.
                        N00077



                                 (e)   Place the reverse gear assembly and align the synchro-
                                       nizer ring slots with the shifting keys.




                        N00078



                                 (f)   Using a press, install the reverse gear assembly.




                        N00079



2002 ECHO (RM884U)

                                                   Author :             Date :               916
MX-36
                      MANUAL TRANSAXLE           -   OUTPUT SHAFT

                                    3.         INSTALL SNAP RING
                                    (a)        Select a snap ring that allows the minimum axial play.
                                          Mark        Thickness mm (in.)    Mark            Thickness mm (in.)
                                           A            2.50 (0.0984)        D                2.68 (0.1055)
                                           B            2.56 (0.1008)        E                2.74 (0.1079)
                                           C            2.62 (0.1031)        F                2.80 (0.1102)
                                    (b)        Using a screwdriver and hammer, tap in the snap ring.
                                    4.         INSPECT 1ST GEAR THRUST CLEARANCE
                           N00080
                                               (See page MX-31 )
                                    5.         INSTALL NEEDLE ROLLER BEARING, SYNCHRONIZ-
                                               ER RING, 2ND GEAR AND 3RD DRIVEN GEAR
                                    (a)        Apply gear oil to the needle roller bearing and install it.
                                    (b)        Place the synchronizer ring on the reverse gear assembly
                                               and align the ring slots with the shifting keys.
                                    (c)        Install the 2nd gear.



                           N00083



                                    (d)        Using a press, install the 3rd driven gear.
                                    6.         INSPECT 2ND GEAR THRUST CLEARANCE
                                               (See page MX-31 )




                           N00084



                                    7.         INSTALL OUTPUT GEAR SPACER, 4TH DRIVEN
                                               GEAR AND REAR BALL BEARING
                                    (a)        Install the output gear spacer.
                                    (b)        Using SST and a press, install the 4th driven gear and
                                               rear ball bearing.
                     SST                       SST 09608-00071



                           N00086




2002 ECHO (RM884U)

                                                            Author :               Date :                        917



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