OUTPUT SHAFT DISASSEMBLY


  1. INSPECT 1ST GEAR THRUST CLEARANCE


    1. A01KHW6E22

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

      Standard clearance
      0.20 to 0.45 mm (0.0079 to 0.0177 in.)
  2. INSPECT 2ND GEAR THRUST CLEARANCE


    1. A01KHW6E23

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

      Standard clearance
      0.10 to 0.25 mm (0.0039 to 0.0098 in.)
  3. INSPECT 3RD GEAR THRUST CLEARANCE


    1. A01KIKDE04

      Using a feeler gauge, measure the thrust clearance of the 3rd gear.

      Standard clearance
      0.10 to 0.25 mm (0.0039 to 0.0098 in.)
  4. INSPECT 1ST GEAR RADIAL CLEARANCE


    1. A01KH70

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

      Standard clearance
      0.020 to 0.073 mm (0.0008 to 0.0029 in.)

      If the clearance is not within the specified values, replace the 1st gear needle roller bearing with a new one.

  5. INSPECT 2ND GEAR RADIAL CLEARANCE


    1. A01KFQT

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

      Standard clearance
      0.015 to 0.068mm (0.0006 to 0.0027 in.)

      If the clearance is not within the specified values, replace the 2nd gear needle roller bearing with a new one.

  6. INSPECT 3RD GEAR RADIAL CLEARANCE


    1. A01KHFA

      Using a dial indicator, measure the radial clearance of the 3rd gear.

      Standard clearance
      0.015 to 0.068 mm (0.0006 to 0.0027 in.)

      If the clearance is not within the specified values, replace the 3rd gear needle roller bearing with a new one.

  7. REMOVE 1ST GEAR


    1. A01KGI3E01

      Using SST and a press, remove the 5th gear, output shaft center bearing, 1st gear thrust washer and 1st gear from the output shaft.

      SST
      09950-00020
  8. REMOVE NO. 1 SYNCHRONIZER RING SET (for 1st Gear (for Triple Type Synchronizer Ring))


    1. A01KIE7

      Remove the No. 1 synchronizer ring set from the output shaft.

  9. REMOVE NO. 1 SYNCHRONIZER RING (for 1st Gear (for Single Type Synchronizer Ring))


    1. A01KGXH

      Remove the No. 1 synchronizer ring from the output shaft.

  10. REMOVE 1ST GEAR THRUST WASHER PIN


    1. A01KGXAE02

      Remove the 1st gear thrust washer pin from the output shaft.

  11. REMOVE 1ST GEAR NEEDLE ROLLER BEARING


    1. A01KE99E02

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

  12. REMOVE 1ST GEAR BEARING SPACER


    1. A01KGO1E03

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

  13. REMOVE BEARING SHAFT SNAP RING


    1. A01KGQA

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

      Note

      Use a piece of cloth to prevent the snap ring from flying off.

  14. REMOVE 2ND GEAR


    1. A01KEDBE01

      Using SST and a press, remove the No. 1 transmission clutch hub, reverse gear, No. 1 synchronizer ring and 2nd gear from the output shaft.

      SST
      09950-00020
  15. REMOVE 2ND GEAR NEEDLE ROLLER BEARING


    1. A01KG60E02

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

  16. REMOVE REVERSE GEAR


    1. A01KHTM

      Remove the reverse gear, 3 No. 1 synchromesh shifting keys and 3 synchromesh shifting compression springs.

      Use a piece of cloth to prevent the shifting keys and the shifting key springs from popping out.

  17. REMOVE CLUTCH HUB SET SHAFT SNAP RING


    1. A01KIFL

      Using snap ring expander, remove the clutch hub set shaft snap ring from the output shaft.

      Note

      Do not damage the sliding surface of the bearing.

  18. REMOVE 3RD GEAR


    1. A01KGGTE01

      Using SST and a press, remove the No. 2 clutch hub with the No. 2 hub sleeve, No. 2 synchronizer ring and 3rd gear from the output shaft.

      SST
      09950-00020
  19. REMOVE 3RD GEAR NEEDLE ROLLER BEARING


    1. A01KGEUE02

      Remove the 3rd gear needle roller bearing from the output shaft.

  20. REMOVE NO. 2 TRANSMISSION HUB SLEEVE


    1. A01KGWT

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