Page 1297 of 2543
(e) Using a dial indicator, check the shaft runout.
Maximum runout:
0.06 mm (0.0024 in.)
If the runout exceeds the maximum, replace the output shaft.
OUTPUT SHAFT ASSEMBLY
HINT: Coat all of the sliding and rotating surface with gear oil
before assembly.
1. INSTALL NO.1 AND NO.2 CLUTCH HUB INTO HUB
SLEEVE
(a) Install the 3 shifting key springs to the clutch hub.
(b) While pushing the shifting key spring with a screw±driver,
install the 3 shifting keys.
(c) While pushing the 3 shifting keys, install the clutch hub to the
hub sleeve, as shown.
2. INSTALL 3RD GEAR AND NO.2 CLUTCH HUB ON
OUTPUT SHAFT
(a) Apply gear oil to the shaft.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
± W58 MANUAL TRANSMISSIONOUTPUT SHAFTMT1±31
Page 1298 of 2543

(c) Using a press, install the 3rd gear and No.2 clutch hub.
3. INSTALL SNAP RING
(a) Select a snap ring that will allow minimum axial play.
Mark Thickness mm (in.)
C±1 1.75±1.80 (0.0689±0.0709)
D 1.80±1.85 (0.0709±0.0728)
11 1.86±1.91 (0.0732±0.0752) 12 1.92±1.97 (0.0756±0.0776)
13
1.98±2.03 (0.0780±0.0799)
14 2.04±2.09 (0.0803±0.0823)
15 2.10±2.15 (0.0827±0.0846)
(b) Using a snap ring expander, install the snap ring.
4. INSPECT 3RD GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 3rd gear thrust clearance.
Standard clearance:
0.10±0.25 mm (0.0039±0.0098 in.)
5. INSTALL 2ND GEAR AND NO.1 CLUTCH HUB
(a) Apply gear oil to the shaft and needle roller bearing.
(b) Place the synchronizer ring on the gear and align the ring
slots with the shifting keys.
(c) Install the needle roller bearing in the 2nd gear.
(d) Using a press, install the 2nd gear and No.1 clutch hub.
6. INSPECT 2ND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 2nd gear thrust clear-
ance.
Standard clearance:
0.10±0.25 mm (0.0039±0.0098 in.)
7. INSTALL LOCKING BALL AND 1ST GEAR ASSEMBLY
(a) Install the locking ball in the shaft.
(b) Apply gear oil to the bearing.
(c) Assemble the 1st gear, synchronizer ring, needle roller
bearing and bearing inner race. MT1±32
± W58 MANUAL TRANSMISSIONOUTPUT SHAFT
Page 1299 of 2543
(d) 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.
8. INSTALL OUTPUT SHAFT CENTER BEARING
Using SST and a press, install the 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.
SST 09506±35010
9. INSPECT 1ST GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 1st gear thrust clearance.
Standard clearance:
0.10±0.25 mm (0.0039±0.0098 in.)
± W58 MANUAL TRANSMISSIONOUTPUT SHAFTMT1±33
Page 1300 of 2543
COUNTER GEAR AND REVERSE
IDLER GEAR
COMPONENTS
COUNTER GEAR COMPONENT PARTS
DISASSEMBLY
REMOVE NO.3 HUB SLEEVE, SHIFTING KEYS AND
SPRINGS FROM SYNCHRONIZER RING
(a) Remove the synchronizer ring assembly from the No.3 hub
sleeve.
(b) Turn the reverse synchronizer pull ring. MT1±34
± W58 MANUAL TRANSMISSIONCOUNTER GEAR AND REVERSE IDLER GEAR
Page 1301 of 2543
(c) Remove the reverse synchronizer ring and 5th synchronizer
ring from the synchronizer pull ring and cone ring.
(d) Turn the reverse synchronizer pull ring, separate the pull ring
and cone ring.
(e) While pushing the shifting key spring to out slide with 2
screwdrivers, remove the 3 shifting keys and key springs,
from the reverse synchronizer ring.
COUNTER GEAR AND REVERSE IDLER
GEAR COMPONENT PARTS
INSPECTION
1. INSPECT COUNTER 5 TH GEAR RADIAL CLEARANCE
(a) Install the spacer, counter 5th gear and needle roller bearing
to the counter gear.
(b) Using a dial indicator, measure the counter 5th gear radial
clearance.
Standard clearance:
0.009±0.060 mm (0.0004±0.0024 in.)
Maximum clearance:
0.150 mm (0.0059 in.)
If the clearance exceeds the maximum, replace the counter
gear or needle roller bearing or counter 5th gear.
± W58 MANUAL TRANSMISSIONCOUNTER GEAR AND REVERSE IDLER GEARMT1±35
Page 1302 of 2543

2. INSPECT COUNTER GEAR
Using a micrometer, measure the outer diameter of the
counter shaft journal.
Minimum diameter:
Part A
26.975 mm (1.0620 in.)
Part B
29.950 mm (1.1791 in.)
3. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE
Using a dial indicator, measure the reverse idler gear radial
clearance.
Standard clearance:
0.041±0.074 mm (0.0016±0.0029 in.)
Maximum clearance:
0.194 mm (0.0076 in.)
If the clearance exceeds the maximum, replace the gear or
shaft.
4. INSPECT CLEARANCE OF REVERSE IDLER GEAR AND
SHIFT ARM SHOE
Using a feeler gauge, measure the clearance between the re-
verse idler gear and shift arm shoe.
Standard clearance:
0.20±0.41 mm (0.008±0.0161 in.)
Maximum clearance:
0.9 mm (0.0354 in.)
If the clearance exceeds the maximum, replace the shift arm
shoe or reverse idler gear.
5. INSPECT 5TH GEAR SYNCHRONIZER RING
(a) Check for wear or damage.
(b) Install the synchronizer pull ring, cone ring and outer ring to
the 5th gear.
(c) Check the braking effect of the synchronizer ring.
Turn the synchronizer ring in one direction while pushing it to
the gear cone. Check that the ring locks.
If it does not lock, replace the synchronizer ring. MT1±36
± W58 MANUAL TRANSMISSIONCOUNTER GEAR AND REVERSE IDLER GEAR
Page 1303 of 2543

6. INSPECT CLEARANCE OF SHIFT FORKS AND HUB
SLEEVES
Using a feeler gauge, measure the clearance between the
hub sleeve and shift fork.
Maximum clearance:
1.0 mm (0.039 in.)
If the clearance exceeds the maximum, replace the shift fork
or hub sleeve.
BEARING REPLACEMENT
1. IF NECESSARY, REPLACE COUNTER GEAR FRONT
BEARING AND SIDE RACE
(a) Using a snap ring expander, remove the snap ring.
(b) Using SST and a press, press out the bearing.
SST 09950±00020
(c) Check the side race for wear or damage.
(d) If necessary, remove the side race.
wUsing SST and a socket wrench, remove the side race.
SST 09950±40010
(e) Using a socket wrench, press in a new bearing, side race and
inner race.
(f) Select a snap ring that will allow minimum axial play.
Mark
Thickness mm (in.)
A 2.05±2.10 (0.0807±0.0827)
B 2.10±2.15 (0.0827±0.0846)
C 2.15±2.20 (0.0846±0.0866)
D 2.20±2.25 (0.0866±0.0886)
E 2.25±2.30 (0.0886±0.0906)
F 2.30±2.35 (0.0906±0.0925)
(g) Using a snap ring expander, install the snap ring.
± W58 MANUAL TRANSMISSIONCOUNTER GEAR AND REVERSE IDLER GEARMT1±37
Page 1304 of 2543
2. IF NECESSARY, REPLACE COUNTER GEAR CENTER
BEARING
(a) Remove the bearing from the counter gear.
(b) Install a new bearing on the counter gear.
HINT: Engage the roller cages.
(c) Using SST, tap out the bearing outer race.
SST 09608±35014 (09608±06020, 09608±06090)
HINT: The outer race will be installed later, as the transmis-
sion is assembled.
COUNTER GEAR ASSEMBLY
INSTALL SYNCHRONIZER RING ASSEMBLY TO NO.3
HUB SLEEVE
(a) Push the synchronizer key spring, install the shifting key and
key spring to the reverse synchronizer ring.
(b) Usin g a scre wd rive r, pu sh th e 3 ke y sp rin g s in to th e
synchronizer ring spring gaps.
(c) Install the synchronizer cone ring to the reverse synchronizer
pull ring and turn the pull ring. MT1±38
± W58 MANUAL TRANSMISSIONCOUNTER GEAR AND REVERSE IDLER GEAR