OUTPUT SHAFT DISASSEMBLY

PROCEDURE

  1. INSPECT 1ST DRIVEN GEAR THRUST CLEARANCE

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  2. INSPECT 1ST DRIVEN GEAR RADIAL CLEARANCE

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  3. INSPECT 2ND DRIVEN GEAR THRUST CLEARANCE

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  4. INSPECT 2ND DRIVEN GEAR RADIAL CLEARANCE

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  5. INSPECT 3RD DRIVEN GEAR THRUST CLEARANCE

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  6. INSPECT 3RD DRIVEN GEAR RADIAL CLEARANCE

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  7. INSPECT 4TH DRIVEN GEAR THRUST CLEARANCE

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  8. INSPECT 4TH DRIVEN GEAR RADIAL CLEARANCE

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  9. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING

    1. C112408

      Using a snap ring expander, remove the output shaft bearing shaft snap ring from the No. 1 output shaft.

  10. REMOVE OUTPUT SHAFT REAR BEARING

    1. C112409N01

      Using SST and a press, remove the output shaft rear bearing from the No. 1 output shaft.

      09201-31010

      09950-00020

  11. REMOVE 3RD DRIVEN GEAR

    1. C112410

      Remove the 3rd driven gear from the No. 1 output shaft.

  12. REMOVE SPACER

    1. C112411

      Remove the spacer from the No. 1 output shaft.

  13. REMOVE NEEDLE ROLLER BEARING

    1. C112412

      Remove the needle roller bearing from the No. 1 output shaft.

  14. REMOVE 3RD DRIVEN GEAR SYNCHRONIZER RING SET

    1. C112413

      Remove the 3rd driven gear synchronizer ring set from the No. 1 output shaft.

  15. REMOVE SHAFT SNAP RING

    1. C112414

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

  16. REMOVE 4TH DRIVEN GEAR

    1. C116210N01

      Using SST and a press, remove the No. 2 transmission hub sleeve, 4th driven gear synchronizer ring set, and 4th driven gear from the No. 1 output shaft.

      09950-00020

  17. REMOVE 4TH DRIVEN GEAR SYNCHRONIZER RING SET

    1. C117924

      Remove the 4th driven gear synchronizer ring set from the 4th driven gear.

  18. REMOVE NO. 2 TRANSMISSION CLUTCH HUB

    1. C275839

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

      Note:

      Pay attention to prevent the balls and synchronizer shifting key springs from scattering.

  19. REMOVE NEEDLE ROLLER BEARING

    1. C112416

      Remove the needle roller bearing from the No. 1 output shaft.

  20. REMOVE SPACER

    1. C112417

      Remove the spacer from the No. 1 output shaft.

  21. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING

    1. C112418

      Using a snap ring expander, remove the output shaft bearing shaft snap ring from the No. 1 output shaft.

  22. REMOVE 2ND DRIVEN GEAR BEARING INNER RACE

    1. C112419

      Remove the 2nd driven gear bearing inner race from the No. 1 output shaft.

  23. REMOVE 2ND DRIVEN GEAR

    1. C112420

      Remove the 2nd driven gear from the No. 1 output shaft.

  24. REMOVE NEEDLE ROLLER BEARING

    1. C112421

      Remove the needle roller bearing from the No. 1 output shaft.

  25. REMOVE SYNCHROMESH SHIFTING KEY BALL

    1. C116562C01

      *a

      Magnet Hand

      Using a magnet hand, remove the synchromesh shifting key ball from the No. 1 output shaft.

  26. REMOVE 2ND DRIVEN GEAR SYNCHRONIZER RING SET

    1. C112422

      Remove the 2nd driven gear synchronizer ring set from the No. 1 output shaft.

  27. REMOVE 1ST DRIVEN GEAR

    1. C145267N01

      Using SST and a press, remove the No. 1 transmission hub sleeve, 1st driven gear synchronizer ring set and 1st driven gear from the No. 1 output shaft.

      09950-00020

  28. REMOVE 1ST DRIVEN GEAR SYNCHRONIZER RING SET

    1. C117926

      Remove the 1st driven synchronizer ring set from the 1st driven gear.

  29. REMOVE NO. 1 TRANSMISSION CLUTCH HUB

    1. C117927

      Remove the No. 1 transmission clutch hub, 3 No. 1 synchromesh shifting keys, 3 balls and 3 synchronizer shifting key springs from the No. 1 transmission hub sleeve.

      Note:

      Pay attention to prevent the balls and synchronizer shifting key springs from scattering.

  30. REMOVE NEEDLE ROLLER BEARING

    1. C112425

      Remove the needle roller bearing from the No. 1 output shaft.

  31. REMOVE OUTPUT SHAFT FRONT BEARING SHAFT SNAP RING

    1. C112426

      Using a snap ring expander, remove the output shaft front bearing shaft snap ring from the No. 1 output shaft.

  32. REMOVE OUTPUT SHAFT FRONT BEARING INNER RACE

    1. C157304N01

      Using SST and a press, remove the output shaft front bearing inner race from the No. 1 output shaft.

      09201-31010

      09950-00020

  33. INSPECT 5TH DRIVEN GEAR THRUST CLEARANCE

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  34. INSPECT 5TH DRIVEN GEAR RADIAL CLEARANCE

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  35. INSPECT 6TH DRIVEN GEAR THRUST CLEARANCE

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  36. INSPECT 6TH DRIVEN GEAR RADIAL CLEARANCE

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  37. INSPECT REVERSE DRIVEN GEAR THRUST CLEARANCE

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  38. INSPECT REVERSE DRIVEN GEAR RADIAL CLEARANCE

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  39. REMOVE NO. 2 OUTPUT SHAFT BEARING SNAP RING

    1. C112395

      Using a snap ring expander, remove the No. 2 output shaft bearing snap ring from the No. 2 output shaft.

  40. REMOVE NO. 2 OUTPUT SHAFT REAR BEARING

    1. C112396N01

      Using SST and a press, remove the No. 2 output shaft rear bearing and 6th driven gear from the No. 2 output shaft.

      09201-31010

      09950-00020

  41. REMOVE NEEDLE ROLLER BEARING

    1. C116204

      Remove the needle roller bearing from the No. 2 output shaft.

  42. REMOVE SPACER

    1. C116203

      Remove the spacer from the No. 2 output shaft.

  43. REMOVE 6TH DRIVEN GEAR SYNCHRONIZER RING

    1. C116202

      Remove the 6th driven gear synchronizer ring from the No. 2 output shaft.

  44. REMOVE SHAFT SNAP RING

    1. C112397

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

  45. REMOVE 5TH DRIVEN GEAR

    1. C112398N01

      Using SST and a press, remove the No. 3 transmission hub sleeve, 5th driving gear synchronizer ring, 5th driven gear, 2 spacers and needle roller bearing from the No. 2 output shaft.

      09950-00020

  46. REMOVE 5TH DRIVEN GEAR SYNCHRONIZER RING

    1. C117928

      Remove the 5th driven gear synchronizer ring from the 5th driven gear.

  47. REMOVE NO. 3 TRANSMISSION CLUTCH HUB

    1. C117929

      Remove the No. 3 transmission clutch hub, 3 No. 1 synchromesh shifting keys, 3 ball and 3 synchronizer shifting key springs from the No. 3 transmission hub sleeve.

      Note:

      Pay attention to prevent the balls and synchronizer shifting key springs from scattering.

  48. REMOVE SHAFT SNAP RING

    1. C112403

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

  49. REMOVE REVERSE DRIVEN GEAR

    1. C112404N01

      Using SST and a press, remove the No. 4 transmission hub sleeve, reverse driven gear synchronizer ring and reverse driven gear from the No. 2 output shaft.

      09950-00020

  50. REMOVE REVERSE DRIVEN GEAR SYNCHRONIZER RING

    1. C117930

      Remove the reverse driven gear synchronizer ring from the reverse driven gear.

  51. REMOVE NO. 4 TRANSMISSION CLUTCH HUB

    1. C117931C03

      *1

      Hub Sleeve

      *2

      Shifting Key

      *3

      Key Spring

      *4

      No. 4 Transmission Clutch Hub

      Remove the No. 4 transmission clutch hub, key spring and shifting key from the No. 4 transmission hub sleeve.

  52. REMOVE NEEDLE ROLLER BEARING

    1. C112406

      Remove the needle roller bearing from the No. 2 output shaft.

  53. REMOVE NO. 2 OUTPUT SHAFT FRONT BEARING

    1. C112407N01

      Using SST and a press, remove the No. 2 output shaft front bearing from the No. 2 output shaft.

      09201-31010

      09950-00020