OUTPUT SHAFT DISASSEMBLY


  1. REMOVE OUTPUT SHAFT REAR BEARING

    A0136W2E01

    1. 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

    A0137ZK

    1. 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.)

  3. INSPECT 2ND GEAR THRUST CLEARANCE

    A0138I1

    1. 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.)

  4. INSPECT 1ST GEAR RADIAL CLEARANCE

    A0138AJ

    1. 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 exceeds the maximum, replace the 1st gear, needle roller bearing or shaft.

  5. INSPECT 2ND GEAR RADIAL CLEARANCE

    A0138TQ

    1. 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 exceeds the maximum, replace the 2nd gear, needle roller bearing or shaft.

  6. REMOVE COUNTER 5TH GEAR SHAFT SNAP RING

    A0136BZ

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

  7. REMOVE 4TH DRIVEN GEAR

    A0138U8

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

  8. REMOVE OUTPUT SHAFT SPACER

    A01369A

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

  9. REMOVE 2ND GEAR

    A01380EE02

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

      SST
      09950-00020

  10. REMOVE 2ND GEAR NEEDLE ROLLER BEARING

    A0136T6

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

  11. REMOVE 2ND GEAR BEARING SPACER

    A0136R0

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

  12. REMOVE 2ND GEAR SYNCHRONIZER RING

    A0137ES

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

  13. REMOVE NO. 1 CLUTCH HUB SHAFT SNAP RING

    A0137OO

    1. Using a snap ring expander, 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

    A01361F

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

  15. REMOVE 1ST GEAR NEEDLE ROLLER BEARING

    A01385C

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

  16. REMOVE OUTPUT SHAFT FRONT BEARING

    A01374YE01

    1. 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

    A0135TT

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