OUTPUT SHAFT DISASSEMBLY

PROCEDURE


  1. INSPECT 3RD GEAR THRUST CLEARANCE

    A01WZKEE01
    *a 3rd Gear Thrust Clearance

    1. Using a feeler gauge, measure the 3rd gear thrust clearance.

      Standard Clearance
      0.10 to 0.45 mm (0.00394 to 0.0177 in.)

      If the clearance is outside the specification, replace the defective gear, spacer or shaft.

  2. INSPECT 5TH GEAR THRUST CLEARANCE

    A01WZKEE07
    *a 5th Gear Thrust Clearance

    1. Using a feeler gauge, measure the 5th gear thrust clearance.

      Standard Clearance
      0.10 to 0.35 mm (0.00394 to 0.0137 in.)

      If the clearance is outside the specification, replace the defective gear, spacer or shaft.

  3. INSPECT 2ND GEAR THRUST CLEARANCE

    A01WZKEE04
    *a 2nd Gear Thrust Clearance

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

      Standard Clearance
      0.10 to 0.35 mm (0.00394 to 0.0137 in.)

      If the clearance is outside the specification, replace the defective gear, spacer or shaft.

  4. INSPECT 1ST GEAR THRUST CLEARANCE

    A01WZKEE06
    *a 1st Gear Thrust Clearance

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

      Standard Clearance
      0.10 to 0.45 mm (0.00394 to 0.0177 in.)

      If the clearance is outside the specification, replace the defective gear, spacer or shaft.

  5. INSPECT 3RD GEAR RADIAL CLEARANCE

    A01X810

    1. Using a dial indicator, measure the 3rd gear radial clearance.

      Standard Clearance
      0.020 to 0.073 mm (0.000788 to 0.00287 in.)

      If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.

  6. INSPECT 5TH GEAR RADIAL CLEARANCE

    A01X5K3

    1. Using a dial indicator, measure the 5th gear radial clearance.

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

      If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.

  7. INSPECT 2ND GEAR RADIAL CLEARANCE

    A01X0HD

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

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

      If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.

  8. INSPECT 1ST GEAR RADIAL CLEARANCE

    A01X693

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

      Standard Clearance
      0.020 to 0.073 mm (0.000788 to 0.00287 in.)

      If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.

  9. REMOVE REVERSE GEAR SNAP RING

    A01X494

    1. Using 2 screwdrivers and a hammer, tap out the snap ring.

      Tech Tips

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

  10. REMOVE 1ST GEAR

    A01X5IZ

    1. Shift the No. 1 transmission hub sleeve to the 2nd gear.

    2. A01XC0ZE01

      Using SST and a press, remove the bearing, 1st gear and synchronizer ring.

      SST
      09555-55010

  11. REMOVE 1ST GEAR NEEDLE ROLLER BEARING


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

  12. REMOVE NO. 1 SYNCHRONIZER RING SET


    1. Remove the No. 1 synchronizer ring from the 1st gear.

  13. REMOVE NO. 1 CLUTCH HUB SHAFT SNAP RING

    A01X5M9

    1. Using 2 screwdrivers and a hammer, tap out the snap ring.

      Tech Tips

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

  14. REMOVE 2ND GEAR

    A01X5EQ

    1. Using a press, remove the 2nd gear and synchronizer ring.

  15. REMOVE 2ND GEAR NEEDLE ROLLER BEARING


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

  16. REMOVE NO. 2 SYNCHRONIZER RING SET


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

  17. REMOVE NO. 1 TRANSMISSION HUB SLEEVE

    A01X7W0E10
    *1 No. 1 Transmission Hub Sleeve
    *2 Shifting Key
    *3 No. 1 Transmission Clutch Hub
    *4 Spring

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

      Tech Tips

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

  18. REMOVE NO. 2 CLUTCH HUB SETTING SHAFT SNAP RING

    A01X5UH

    1. Using 2 screwdrivers and a hammer, tap out the snap ring.

      Tech Tips

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

  19. REMOVE 3RD GEAR

    A01X6SX

    1. Shift the No. 3 transmission hub sleeve to the 5th gear.

    2. A01WZRHE01

      Using SST and a press, remove the 3rd gear and synchronizer ring.

      SST
      09555-55010

  20. REMOVE 3RD GEAR NEEDLE ROLLER BEARING


    1. Remove the 3rd gear needle roller bearing from the output shaft.

  21. REMOVE NO. 3 SYNCHRONIZER RING SET


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

  22. REMOVE NO. 2 TRANSMISSION HUB SLEEVE

    A01X7W0E11
    *1 No. 2 Transmission Hub Sleeve
    *2 Shifting Key
    *3 Spring
    *4 No. 2 Transmission Clutch Hub

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

      Tech Tips

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

  23. REMOVE NO. 3 TRANSMISSION CLUTCH HUB SHAFT SNAP RING

    A01X3RT

    1. Using 2 screwdrivers and a hammer, tap out the snap ring.

      Tech Tips

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

  24. REMOVE 5TH GEAR

    A01X036E01

    1. Using SST and a press, remove the 5th gear and synchronizer ring.

      SST
      09555-55010

  25. REMOVE 5TH COUNTER GEAR BEARING


    1. Remove the 5th counter gear bearing from the output shaft.

  26. REMOVE NO. 3 SYNCHRONIZER RING SET


    1. Remove the No. 3 synchronizer ring from the 5th gear.

  27. REMOVE NO. 3 TRANSMISSION HUB SLEEVE

    A01X7W0E12
    *1 No. 3 Transmission Hub Sleeve
    *2 Shifting Key
    *3 No. 3 Transmission Clutch Hub
    *4 Spring

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

      Tech Tips

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