OUTPUT SHAFT DISASSEMBLY

PROCEDURE

1. REMOVE OUTPUT SHAFT END COVER

   1. Hold the output shaft in a vise between aluminum plates.

      Note:

      Do not overtighten the vise.

   2. 

      Using an oil pan seal cutter and a hammer, make a clearance between the output shaft end cover and output shaft as shown in the illustration.

   3. 

      Using a clip remover, remove the output shaft end cover from the output shaft.

2. REMOVE OUTPUT SHAFT REAR BEARING HOLE SNAP RING

   1. 

      Using 2 screwdrivers and a hammer, remove the output shaft rear bearing hole snap ring from the output shaft.

      Tip:

      Use a piece of cloth to prevent the output shaft rear bearing hole snap ring from flying off.

3. REMOVE OUTPUT SHAFT REAR BEARING

   1. 

      *a

      Snap Ring

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

      09950-00020

      Note:

      • Do not excessively tighten SST.

      • Support the output shaft by hand to prevent it from dropping.

      • Be careful not to deform the snap ring.

4. REMOVE OUTPUT SHAFT SPACER

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

5. REMOVE 4TH GEAR

   1. Remove the 4th gear from the output shaft.

6. REMOVE NO. 2 TRANSMISSION CLUTCH HUB WITH NO. 2 TRANSMISSION HUB SLEEVE

   1. 

      *1	Output Shaft Spacer
      *2	4th Gear
      *3	No. 2 Synchronizer Ring Set
      *4	No. 2 Transmission Clutch Hub with No. 2 Transmission Hub Sleeve

      Remove the 2 No. 2 synchronizer ring sets and No. 2 transmission clutch hub with No. 2 transmission hub sleeve from the output shaft.

      Note:

      Do not remove the No. 2 transmission clutch hub as the synchromesh shifting key balls, compression springs, and No. 2 synchromesh shifting keys may fly out.

7. REMOVE NO. 2 TRANSMISSION CLUTCH HUB

   Tip:

   Perform this procedure only when replacing the 3 synchromesh shifting key balls, 3 compression springs or 3 No. 2 synchromesh shifting keys.

   1. 

      *a

      Matchmark

      Put matchmarks on the No. 2 transmission clutch hub and No. 2 transmission hub sleeve.

   2. Remove the No. 2 transmission hub sleeve, 3 synchromesh shifting key balls, 3 compression springs and 3 No. 2 synchromesh shifting keys from the No. 2 transmission clutch hub.

      Note:

      Take care to prevent the synchromesh shifting key balls and compression springs from scattering.

      

      *1	No. 2 Transmission Hub Sleeve	*2	Synchromesh Shifting Key Ball
      *3	Compression Spring	*4	No. 2 Synchromesh Shifting Key
      *5	No. 2 Transmission Clutch Hub	-	-

8. REMOVE NO. 2 3RD GEAR SHAFT SNAP RING

   1. 

      Hold the output shaft in a vise between aluminum plates.

      Note:

      Do not overtighten the vise.

   2. Using 2 screwdrivers and a hammer, remove the No. 2 3rd gear shaft snap ring from the output shaft.

      Tip:

      Use a piece of cloth to prevent the No. 2 3rd gear shaft snap ring from flying off.

9. REMOVE 3RD GEAR

   

   1. Remove the 3rd gear from the output shaft.

10. REMOVE NO. 1 3RD REAR SHAFT SNAP RING

    1. 

       Using 2 screwdrivers and a hammer, remove the No. 1 3rd gear shaft snap ring from the output shaft.

       Note:

       Use a piece of cloth to prevent the No. 1 3rd gear shaft snap ring from flying off.

11. REMOVE 2ND GEAR

    1. Remove the 2nd gear from the output shaft.

12. REMOVE NO. 1 TRANSMISSION CLUTCH HUB WITH NO. 1 TRANSMISSION HUB SLEEVE

    1. 

       *1	2nd Gear
       *2	No. 1 Synchronizer Ring Set
       *3	No. 1 Transmission Clutch Hub with No. 1 Transmission Hub Sleeve

       Remove the 2 No. 1 synchronizer ring sets and No. 1 transmission clutch hub with No. 1 transmission hub sleeve from the output shaft.

       Note:

       Do not remove the No. 1 transmission clutch hub as the synchromesh shifting key balls, compression springs, ball seats, and No. 1 synchromesh shifting keys may fly out.

13. REMOVE NO. 1 TRANSMISSION CLUTCH HUB

    Tip:

    Perform this procedure only when replacing the 3 synchromesh shifting key balls, 3 ball seats, 3 compression springs or 3 No. 1 synchromesh shifting keys.

    1. 

       *a

       Matchmark

       Put matchmarks on the No. 1 transmission clutch hub and No. 1 transmission hub sleeve.

    2. Remove the No. 1 transmission hub sleeve, 3 synchromesh shifting key balls, 3 compression springs, 3 ball seats and 3 No. 1 synchromesh shifting keys from the No. 1 transmission clutch hub.

       Note:

       Take care to prevent the synchromesh shifting key balls, ball seats and compression springs from scattering.

       

       *1	No. 1 Transmission Hub Sleeve	*2	Synchromesh Shifting Key Ball
       *3	Ball Seat	*4	Compression Spring
       *5	No. 1 Synchromesh Shifting Key	*6	No. 1 Transmission Clutch Hub

14. REMOVE NO. 2 1ST GEAR SHAFT SNAP RING

    1. 

       Using 2 screwdrivers and a hammer, remove the No. 2 1st gear shaft snap ring from the output shaft.

       Tip:

       Use a piece of cloth to prevent the No. 2 1st gear shaft snap ring from flying off.

15. REMOVE 1ST GEAR

    

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

16. REMOVE NO. 1 1ST GEAR SHAFT SNAP RING

    1. 

       Using 2 screwdrivers and a hammer, remove the No. 1 1st gear shaft snap ring from the output shaft.

       Tip:

       Use a piece of cloth to prevent the No. 1 1st gear shaft snap ring from flying off.

17. REMOVE OUTPUT SHAFT FRONT BEARING

    1. 

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

       09950-00020

       Note:

       • Do not excessively tighten SST.

       • Support the output shaft by hand to prevent it from dropping.