OUTPUT SHAFT DISASSEMBLY

PROCEDURE

  1. INSPECT 1ST GEAR THRUST CLEARANCE

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  2. INSPECT 2ND GEAR THRUST CLEARANCE

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  3. INSPECT 1ST GEAR RADIAL CLEARANCE

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  4. INSPECT 2ND GEAR RADIAL CLEARANCE

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  5. REMOVE 6TH DRIVEN GEAR

    1. C278734C01

      *a

      Turn

      *b

      Hold

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

      09950-40011

      09951-04010

      09952-04010

      09953-04020

      09954-04010

      09955-04021

      09957-04010

      09958-04011

      09950-60010

      09951-00180

      09951-00270

      09952-06010

  6. REMOVE OUTPUT GEAR SPACER

    1. C199106

      Remove the output gear spacer from the output shaft.

  7. REMOVE 4TH DRIVEN GEAR

    1. C199107N01

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

      09527-10011

      09950-40011

      09957-04010

      09950-60010

      09951-00180

      09951-00270

      09952-06010

      Note:

      Support the output shaft by hand to prevent it from falling.

  8. REMOVE OUTPUT GEAR SPACER

    1. C199108

      Remove the output gear spacer from the output shaft.

  9. REMOVE 2ND GEAR

    1. C278739C01

      *a

      Turn

      *b

      Hold

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

      09950-40011

      09951-04010

      09952-04010

      09953-04020

      09954-04030

      09955-04021

      09957-04010

      09958-04011

      09950-60010

      09951-00180

      09951-00270

      09952-06010

  10. REMOVE 2ND GEAR NEEDLE ROLLER BEARING

    1. C199110

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

  11. REMOVE INNER 2ND GEAR BEARING RACE

    1. C199111

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

  12. REMOVE NO. 1 SYNCHRONIZER RING SET (for 2nd Gear)

    1. C194361C01

      *1

      Inner Ring

      *2

      Middle Ring

      *3

      Outer Ring

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

  13. REMOVE REVERSE GEAR

    1. C278735

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

  14. REMOVE NO. 1 SYNCHROMESH SHIFTING KEY

    1. C199112

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

  15. REMOVE NO. 1 TRANSMISSION CLUTCH HUB

    1. C199113

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

  16. REMOVE NO. 1 SYNCHRONIZER RING SET (for 1st Gear)

    1. C194365C01

      *1

      Outer Ring

      *2

      Middle Ring

      *3

      Inner Ring

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

  17. REMOVE 1ST GEAR

    1. C194366

      Remove the 1st gear from the output shaft.

  18. REMOVE 1ST GEAR NEEDLE ROLLER BEARING

    1. C194367

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

  19. REMOVE 1ST GEAR BUSH

    1. C194368

      Remove the 1st gear bush from the output shaft.

  20. REMOVE FRONT OUTPUT SHAFT BEARING

    1. C278736E01

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

      09950-00020

      09950-00030

      09950-40011

      09957-04010

      09950-60010

      09951-00180

      09951-00340

      09952-06010