OUTPUT SHAFT DISASSEMBLY


  1. INSPECT 1ST GEAR THRUST CLEARANCE


    1. A01DQ0R

      Using a dial indicator, measure the thrust clearance.

      Standard clearance
      0.20 to 0.45 mm (0.00787 to 0.0177 in.)

      • If the clearance is not as specified, replace the No. 1 synchronizer ring set.

  2. INSPECT 2ND GEAR THRUST CLEARANCE


    1. A01DPIW

      Using a dial indicator, measure the thrust clearance.

      Standard clearance
      0.10 to 0.25 mm (0.00394 to 0.00984 in.)

      • If the clearance is not as specified, replace the No. 1 synchronizer ring set.

  3. INSPECT 3RD GEAR THRUST CLEARANCE


    1. A01DOYME01

      Using a feeler gauge, measure the thrust clearance.

      Standard clearance
      0.10 to 0.25 mm (0.00394 to 0.00984 in.)

      • If the clearance is not as specified, replace the No. 2 synchronizer ring set.

  4. INSPECT 1ST GEAR RADIAL CLEARANCE


    1. A01DPERE01

      Using a dial indicator, measure the radial clearance.

      Standard clearance
      0.020 to 0.073 mm (0.000785 to 0.00287 in.)

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

  5. INSPECT 2ND GEAR RADIAL CLEARANCE


    1. A01DQ8NE01

      Using a dial indicator, measure the radial clearance.

      Standard clearance
      0.015 to 0.068 mm (0.000591 to 0.00267 in.)

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

  6. INSPECT 3RD GEAR RADIAL CLEARANCE


    1. A01DOGHE01

      Using a dial indicator, measure the radial clearance.

      Standard clearance
      0.015 to 0.068 mm (0.000591 to 0.00267 in.)

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

  7. REMOVE 1ST GEAR


    1. A01DP9RE01

      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)


    1. A01DQF0

      Remove the synchronizer rings from the output shaft.

  9. REMOVE 1ST GEAR THRUST WASHER PIN


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

  10. REMOVE 1ST GEAR NEEDLE ROLLER BEARING


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

  11. REMOVE 1ST GEAR BEARING SPACER


    1. Remove the bearing spacer from the output shaft.

  12. REMOVE BEARING SHAFT SNAP RING


    1. A01DT7TE01

      Using 2 screwdrivers and a hammer, tap off the snap ring from the output shaft.

      Note

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

  13. REMOVE 2ND GEAR


    1. A01DTPOE01

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

      SST
      09950-00020

  14. REMOVE 2ND GEAR NEEDLE ROLLER BEARING


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

  15. REMOVE REVERSE GEAR


    1. A01DLYME01

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

      Note

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

  16. REMOVE CLUTCH HUB SET SHAFT SNAP RING


    1. A01DQ1VE01

      Using a snap ring expander, remove the snap ring from the output shaft.

      Note

      Do not damage the sliding surface of the bearing.

  17. REMOVE 3RD GEAR


    1. A01DOE5E01

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

      SST
      09950-00020

  18. REMOVE 3RD GEAR NEEDLE ROLLER BEARING


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

  19. REMOVE NO. 2 TRANSMISSION HUB SLEEVE


    1. A01DPX5E01

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