OUTPUT SHAFT > DISASSEMBLY

for Preparation Click here



1. INSPECT 1ST GEAR THRUST CLEARANCE


    C194350

  1. Using a dial indicator, measure the 1st gear thrust clearance.

    Standard clearance:
    0.20 to 0.38 mm (0.00787 to 0.0150 in.)

    Maximum clearance:
    0.38 mm (0.0150 in.)

    If the clearance exceeds the maximum, replace the No. 1 transmission clutch hub, 1st gear bush or 1st gear.



2. INSPECT 2ND GEAR THRUST CLEARANCE


    C194351

  1. Using a dial indicator, measure the 2nd gear thrust clearance.

    Standard clearance:
    0.15 to 0.33 mm (0.00591 to 0.0130 in.)

    Maximum clearance:
    0.33 mm (0.0130 in.)

    If the clearance exceeds the maximum, replace the inner 2nd gear bearing race, No. 1 transmission clutch hub, 2nd gear or 3rd driven gear.



3. INSPECT 1ST GEAR RADIAL CLEARANCE


    C194352

  1. Using a dial indicator, measure the 1st gear radial clearance.

    Standard clearance:
    0.009 to 0.077 mm (0.000354 to 0.00303 in.)

    Maximum clearance:
    0.077 mm (0.00303 in.)

    If the clearance exceeds the maximum, replace the 1st gear, 1st gear needle roller bearing or output shaft.



4. INSPECT 2ND GEAR RADIAL CLEARANCE


    C194353

  1. Using a dial indicator, measure the 2nd gear radial clearance.

    Standard clearance:
    0.009 to 0.077 mm (0.000354 to 0.00303 in.)

    Maximum clearance:
    0.077 mm (0.00303 in.)

    If the clearance exceeds the maximum, replace the 2nd gear, 2nd gear needle roller bearing or output shaft.



5. REMOVE 6TH DRIVEN GEAR


    C194354E01

  1. Using SST and a press, remove the rear output shaft bearing and 6th driven gear from the output shaft.

    SST
    09527-21011  
    09950-60010   (09951-00290)
    09950-70010   (09951-07100)

    NOTICE:
    Support the output shaft by hand to prevent it from dropping off.



6. REMOVE OUTPUT GEAR SPACER


    C194355E01

  1. Remove the output gear spacer from the output shaft.



7. REMOVE 4TH DRIVEN GEAR


    C194356E01

  1. Using SST and a press, remove the 5th driven gear and 4th driven gear from the output shaft.

    SST
    09527-21011  
    09950-60010   (09951-00290)

    NOTICE:
    Support the output shaft by hand to prevent it from dropping off.



8. REMOVE OUTPUT GEAR SPACER


    C194357E01

  1. Remove the output gear spacer from the output shaft.



9. REMOVE 2ND GEAR


    C194358E01

  1. Using SST and a press, remove the 3rd driven gear with the 2nd gear from the output shaft.

    SST
    09950-00020  
    09950-60010   (09951-00290)

    NOTICE:
    1. Do not tighten SST excessively.
    2. Support the output shaft by hand to prevent it from dropping off.



10. REMOVE 2ND GEAR NEEDLE ROLLER BEARING


    C194359E01

  1. Remove the 2nd gear needle roller bearing from the output shaft.



11. REMOVE INNER 2ND GEAR BEARING RACE


    C194360E01

  1. Remove the inner 2nd gear bearing race from the output shaft.



12. REMOVE NO. 1 SYNCHRONIZER RING SET (FOR 2ND GEAR)


    C194361

  1. Remove the No. 1 synchronizer ring set from the reverse gear.



13. REMOVE REVERSE GEAR


    C194362E01

  1. Remove the reverse gear from the No. 1 transmission clutch hub.



14. REMOVE NO. 1 SYNCHROMESH SHIFTING KEY


    C194363

  1. Remove the 3 No. 1 synchromesh shifting keys from the No. 1 transmission clutch hub.



15. REMOVE NO. 1 TRANSMISSION CLUTCH HUB


    C194364

  1. Remove the No. 1 transmission clutch hub from the output shaft.



16. REMOVE NO. 1 SYNCHRONIZER RING SET (FOR 1ST GEAR)


    C194365

  1. Remove the No. 1 synchronizer ring set from the 1st gear.



17. REMOVE 1ST GEAR


    C194366

  1. Remove the 1st gear from the output shaft.



18. REMOVE 1ST GEAR NEEDLE ROLLER BEARING


    C194367

  1. Remove the 1st gear needle roller bearing from the output shaft.



19. REMOVE 1ST GEAR BUSH


    C194368

  1. Remove the 1st gear bush from the output shaft.



20. REMOVE FRONT OUTPUT SHAFT BEARING


    C194369E01

  1. Using SST and a press, remove the front output shaft bearing from the output shaft.

    SST
    09950-00020  
    09950-60010   (09951-00290)
    09950-70010   (09951-07100)

    NOTICE:
    1. Do not tighten SST excessively.
    2. Support the output shaft by hand to prevent it from dropping off.