OUTPUT SHAFT DISASSEMBLY


  1. REMOVE OUTPUT SHAFT REAR BEARING


    1. A0136W2E03

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

      SST
      09950-60010   ( 09951-00220 )
      09950-70010   ( 09951-07100 )

  2. INSPECT 1ST GEAR THRUST CLEARANCE


    1. A0137ZKE01

      Using a feeler gauge, measure the 1st gear thrust clearance.

      Standard clearance
      0.10 to 0.35 mm (0.00394 to 0.0137 in.)
      Maximum clearance
      0.35 mm (0.0137 in.)

      If the clearance is more than the maximum, replace the No. 1 transmission clutch hub, 1st gear or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  3. INSPECT 2ND GEAR THRUST CLEARANCE


    1. A0138I1E01

      Using a feeler gauge, measure the 2nd gear thrust clearance.

      Standard clearance
      0.10 to 0.55 mm (0.00394 to 0.0216 in.)
      Maximum clearance
      0.55 mm (0.0216 in.)

      If the clearance is more than the maximum, replace the 2nd gear, No. 1 transmission clutch hub, 3rd driven gear or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  4. INSPECT 1ST GEAR RADIAL CLEARANCE


    1. A0138AJE01

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

      Standard clearance
      0.015 to 0.056 mm (0.000591 to 0.00220 in.)
      Maximum clearance
      0.056 mm (0.00220 in.)

      If the clearance is more than the maximum, replace the 1st gear needle roller bearing, 1st gear or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  5. INSPECT 2ND GEAR RADIAL CLEARANCE


    1. A0138TQE01

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

      Standard clearance
      0.015 to 0.056 mm (0.000591 to 0.00220 in.)
      Maximum clearance
      0.056 mm (0.00220 in.)

      If the clearance is more than the maximum, replace the 2nd gear needle roller bearing, 2nd gear or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  6. REMOVE COUNTER 5TH GEAR SHAFT SNAP RING


    1. A0136BZE01

      Using 2 screwdrivers and a hammer, remove the counter 5th gear shaft snap ring from the output shaft.

      Tech Tips

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

  7. REMOVE 4TH DRIVEN GEAR


    1. A0138U8E01

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

  8. REMOVE OUTPUT SHAFT SPACER


    1. A01369AE01

      Remove the output shaft spacer from the output shaft.

  9. REMOVE 2ND GEAR


    1. A01380EE03

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

      SST
      09950-00020

  10. REMOVE 2ND GEAR NEEDLE ROLLER BEARING


    1. A0136T6E01

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

  11. REMOVE 2ND GEAR BEARING SPACER


    1. A0136R0E01

      Remove the 2nd gear bearing spacer from the output shaft.

  12. REMOVE 2ND GEAR SYNCHRONIZER RING


    1. A0137ESE01

      Remove the 2nd gear synchronizer ring from the reverse gear.

  13. REMOVE NO. 1 CLUTCH HUB SHAFT SNAP RING


    1. A0136A8

      Using 2 screwdrivers, remove the No. 1 clutch hub shaft snap ring from the output shaft.

      Note

      Do not damage the journal surface of the output shaft.

  14. REMOVE 1ST GEAR


    1. A01361FE01

      Using a press, remove the No. 1 transmission clutch hub set and the 1st gear from the output shaft.

  15. REMOVE 1ST GEAR NEEDLE ROLLER BEARING


    1. A01385C

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

  16. REMOVE OUTPUT SHAFT FRONT BEARING


    1. A01374YE03

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

      SST
      09950-00020

  17. REMOVE NO. 1 TRANSMISSION CLUTCH HUB


    1. A0135TTE01

      Remove the 2 No. 1 shifting key springs, 3 No. 1 shifting keys and the reverse gear from the No. 1 transmission clutch hub.