OUTPUT SHAFT DISASSEMBLY

PROCEDURE


  1. INSPECT 1ST DRIVEN GEAR THRUST CLEARANCE

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  2. INSPECT 1ST DRIVEN GEAR RADIAL CLEARANCE

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  3. INSPECT 2ND DRIVEN GEAR THRUST CLEARANCE

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  4. INSPECT 2ND DRIVEN GEAR RADIAL CLEARANCE

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  5. INSPECT 3RD DRIVEN GEAR THRUST CLEARANCE

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  6. INSPECT 3RD DRIVEN GEAR RADIAL CLEARANCE

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  7. INSPECT 4TH DRIVEN GEAR THRUST CLEARANCE

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  8. INSPECT 4TH DRIVEN GEAR RADIAL CLEARANCE

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  9. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A004PSC

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

  10. REMOVE OUTPUT SHAFT FRONT BEARING


    1. A004N01E01

      Using SST and a press, press out the output shaft front bearing from the No. 1 output shaft.

      SST
      09201-31010
      09950-00020

  11. REMOVE 3RD DRIVEN GEAR


    1. A004P5N

      Remove the 3rd driven gear from the No. 1 output shaft.

  12. REMOVE SPACER


    1. A004Q1B

      Remove the spacer from the No. 1 output shaft.

  13. REMOVE NEEDLE ROLLER BEARING


    1. A004OFG

      Remove the needle roller bearing from the No. 1 output shaft.

  14. REMOVE 3RD DRIVEN GEAR SYNCHRONIZER RING SET


    1. A004R5U

      Remove the 3rd driven gear synchronizer ring set from the No. 1 output shaft.

  15. REMOVE SHAFT SNAP RING


    1. A004STG

      Using 2 screwdrivers and a hammer, tap out the shaft snap ring from the No. 1 output shaft.

  16. REMOVE 4TH DRIVEN GEAR


    1. A004OWYE01

      Using SST and a press, press out the No. 2 transmission hub sleeve, 4th driven gear synchronizer ring set and 4th driven gear from the No. 1 output shaft.

      SST
      09950-00020

  17. REMOVE 4TH DRIVEN GEAR SYNCHRONIZER RING SET


    1. A004PQT

      Remove the 4th driven gear synchronizer ring set from the 4th driven gear.

  18. REMOVE NO. 2 TRANSMISSION CLUTCH HUB


    1. A004R5A

      Remove the clutch hub, 3 keys, 3 balls and 3 key springs from the hub sleeve.

      Note

      Pay attention to prevent the balls and springs from scattering.

  19. REMOVE NEEDLE ROLLER BEARING


    1. A004U3A

      Remove the 2 pieces of the needle roller bearing from the No. 1 output shaft.

  20. REMOVE SPACER


    1. A004PQC

      Remove the spacer from the No. 1 output shaft.

  21. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A004T9X

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

  22. REMOVE INNER 2ND DRIVEN GEAR BEARING RACE


    1. A004SZ4

      Remove the inner 2nd driven gear bearing race from the No. 1 output shaft.

  23. REMOVE 2ND DRIVEN GEAR


    1. A004OJB

      Remove the 2nd driven gear from the No. 1 output shaft.

  24. REMOVE NEEDLE ROLLER BEARING


    1. A004TC6

      Remove the needle roller bearing from the No. 1 output shaft.

  25. REMOVE SYNCHROMESH SHIFTING KEY BALL


    1. A004RWDE01
      Text in Illustration
      *1 Magnet Hand

      Using a magnet hand, remove the synchromesh shifting key ball from the No. 1 output shaft.

  26. REMOVE 2ND DRIVEN GEAR SYNCHRONIZER RING SET


    1. A004NPF

      Remove the 2nd driven gear synchronizer ring set from the No. 1 output shaft.

  27. REMOVE 1ST DRIVEN GEAR


    1. A004PY5E01

      Using SST and a press, press out the No. 1 transmission hub sleeve, 1st driven gear synchronizer ring set and 1st driven gear from the No. 1 output shaft.

      SST
      09950-00020

  28. REMOVE 1ST DRIVEN GEAR SYNCHRONIZER RING SET


    1. A004TBY

      Remove the synchronizer ring set from the 1st driven gear.

  29. REMOVE NO. 1 TRANSMISSION CLUTCH HUB


    1. A004Q7H

      Remove the clutch hub, 3 keys, 3 balls and 3 key springs from the hub sleeve.

      Note

      Pay attention to prevent the balls and springs from scattering.

  30. REMOVE NEEDLE ROLLER BEARING


    1. A004MR5

      Remove the needle roller bearing from the No. 1 output shaft.

  31. REMOVE OUTPUT SHAFT FRONT BEARING SHAFT SNAP RING


    1. A004QGB

      Using a snap ring expander, remove the output shaft front bearing shaft snap ring from the No. 1 output shaft.

  32. REMOVE OUTPUT SHAFT FRONT BEARING


    1. A004PIGE01

      Using SST and a press, press out the output shaft front bearing from the No. 1 output shaft.

      SST
      09201-31010
      09950-00020

  33. INSPECT 5TH DRIVEN GEAR THRUST CLEARANCE

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  34. INSPECT 5TH DRIVEN GEAR RADIAL CLEARANCE

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  35. INSPECT 6TH DRIVEN GEAR THRUST CLEARANCE

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  36. INSPECT 6TH DRIVEN GEAR RADIAL CLEARANCE

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  37. INSPECT REVERSE DRIVEN GEAR THRUST CLEARANCE

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  38. INSPECT REVERSE DRIVEN GEAR RADIAL CLEARANCE

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  39. REMOVE NO. 2 OUTPUT SHAFT BEARING SNAP RING


    1. A004RY7

      Using a snap ring expander, remove the No. 2 output shaft bearing snap ring from the No. 2 output shaft.

  40. REMOVE NO. 2 OUTPUT SHAFT REAR BEARING


    1. A004N8JE01

      Using SST and a press, press out the rear bearing and 6th driven gear from the No. 2 output shaft.

      SST
      09201-31010
      09950-00020

  41. REMOVE NEEDLE ROLLER BEARING


    1. A004TUZ

      Remove the 2 pieces of the needle roller bearing from the No. 2 output shaft.

  42. REMOVE SPACER


    1. A004O3V

      Remove the spacer from the No. 2 output shaft.

  43. REMOVE 6TH GEAR SYNCHRONIZER RING


    1. A004OMV

      Remove the 6th gear synchronizer ring from the No. 2 output shaft.

  44. REMOVE SHAFT SNAP RING


    1. A004NUK

      Using 2 screwdrivers and a hammer, tap out the shaft snap ring from the No. 2 output shaft.

  45. REMOVE 5TH DRIVEN GEAR


    1. A004O35E01

      Using SST and a press, press out the No. 3 transmission hub sleeve, 5th driven gear synchronizer ring and 5th driven gear from the No. 2 output shaft.

      SST
      09950-00020

  46. REMOVE 5TH DRIVEN GEAR SYNCHRONIZER RING


    1. A004RDH

      Remove the 5th driven gear synchronizer ring from the 5th driven gear.

  47. REMOVE NO. 3 TRANSMISSION CLUTCH HUB


    1. A004SGD

      Remove the No. 3 transmission clutch hub, 3 keys, 3 balls and 3 key springs from the hub sleeve.

      Note

      Pay attention to prevent the balls and springs from scattering.

  48. REMOVE OUTPUT SHAFT COLLAR


    1. A004Q83

      Remove the output shaft collar from the No. 2 output shaft.

  49. REMOVE 5TH GEAR NEEDLE ROLLER BEARING


    1. A004OYU

      Remove the 2 pieces of the 5th gear needle roller bearing from the No. 2 output shaft.

  50. REMOVE 5TH GEAR BEARING SPACER


    1. A004R4Z

      Remove the 5th gear bearing spacer from the No. 2 output shaft.

  51. REMOVE SHAFT SNAP RING


    1. A004Q52

      Using 2 screwdrivers and a hammer, remove the shaft snap ring from the No. 2 output shaft.

  52. REMOVE REVERSE DRIVEN GEAR


    1. A004U08E01

      Using SST and a press, press out the No. 4 transmission hub sleeve, reverse driven gear synchronizer ring set and reverse driven gear from the No. 2 output shaft.

      SST
      09950-00020

  53. REMOVE REVERSE DRIVEN GEAR SYNCHRONIZER RING


    1. A004TLA

      Remove the reverse driven gear synchronizer ring from the revers gear.

  54. REMOVE NO. 4 TRANSMISSION CLUTCH HUB


    1. A004SJK

      Remove the No. 4 transmission clutch hub, synchromesh shifting key spring and 2 synchromesh shifting keys from the transmission hub sleeve.

  55. REMOVE NEEDLE ROLLER BEARING


    1. A004SAM

      Remove the needle roller bearing from the No. 2 output shaft.

  56. REMOVE NO. 2 OUTPUT SHAFT FRONT BEARING


    1. A004O3YE01

      Using SST and a press, press out the No. 2 output shaft front bearing from the No. 2 output shaft.

      SST
      09201-31010
      09950-00020