OUTPUT SHAFT DISASSEMBLY


  1. REMOVE OUTPUT SHAFT REAR BEARING

    A0136W2E02

    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 (0.0039 to 0.0138 in.)
      Maximum clearance
      0.35 mm (0.0138 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 (0.0039 to 0.0217 in.)
      Maximum clearance
      0.55 mm (0.0217 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 (0.0006 to 0.0022 in.)
      Maximum clearance
      0.056 mm (0.0022 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 (0.0006 to 0.0022 in.)
      Maximum clearance
      0.056 mm (0.0022 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 with 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


    1. A01380EE02

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

      SST
      09950-00020

      Tech Tips

      Support the output shaft by hand to prevent it form dropping off.

  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 CLUTCH HUB NO.1 SHAFT SNAP RING

    A0137OO

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

      Tech Tips

      Do not damage the journal surface of the output shaft.

  14. REMOVE 1ST GEAR

    A01361F

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

  15. REMOVE 1ST GEAR NEEDLE ROLLER BEARING

    A0138NB

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

  16. REMOVE OUTPUT SHAFT FRONT BEARING


    1. A01374YE02

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

      SST
      09950-00020

  17. REMOVE TRANSMISSION CLUTCH HUB NO.1

    A0135TT

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