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. A002N2Z

      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. A002LR9E01

      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. A002QFK

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

  12. REMOVE SPACER


    1. A002LT4

      Remove the spacer from the No. 1 output shaft.

  13. REMOVE NEEDLE ROLLER BEARING


    1. A002Q92

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

  14. REMOVE 3RD DRIVEN GEAR SYNCHRONIZER RING SET


    1. A002P3V

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

  15. REMOVE SHAFT SNAP RING


    1. A002NY4

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

  16. REMOVE 4TH DRIVEN GEAR


    1. A002N9IE01

      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. A002Q6U

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

  18. REMOVE NO. 2 TRANSMISSION CLUTCH HUB


    1. A002LP0

      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. A002MXU

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

  20. REMOVE SPACER


    1. A002PPH

      Remove the spacer from the No. 1 output shaft.

  21. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A002N50

      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. A002N39

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

  23. REMOVE 2ND DRIVEN GEAR


    1. A002Q75

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

  24. REMOVE NEEDLE ROLLER BEARING


    1. A002Q1G

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

  25. REMOVE SYNCHROMESH SHIFTING KEY BALL


    1. A002LYHE01
      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. A002P8Q

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

  27. REMOVE 1ST DRIVEN GEAR


    1. A002OOFE01

      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. A002LRR

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

  29. REMOVE NO. 1 TRANSMISSION CLUTCH HUB


    1. A002MKE

      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. A002LN2

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

  31. REMOVE OUTPUT SHAFT FRONT BEARING SHAFT SNAP RING


    1. A002O91

      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. A002O8RE01

      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. A002MUO

      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. A002LVEE01

      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. A002NNN

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

  42. REMOVE SPACER


    1. A002PYA

      Remove the spacer from the No. 2 output shaft.

  43. REMOVE 6TH GEAR SYNCHRONIZER RING


    1. A002OLJ

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

  44. REMOVE SHAFT SNAP RING


    1. A002O77

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

  45. REMOVE 5TH DRIVEN GEAR


    1. A002OVEE01

      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. A002O8I

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

  47. REMOVE NO. 3 TRANSMISSION CLUTCH HUB


    1. A002QG0

      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. A002O4B

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

  49. REMOVE 5TH GEAR NEEDLE ROLLER BEARING


    1. A002N2R

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

  50. REMOVE 5TH GEAR BEARING SPACER


    1. A002OWY

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

  51. REMOVE SHAFT SNAP RING


    1. A002P26

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

  52. REMOVE REVERSE DRIVEN GEAR


    1. A002QJJE01

      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. A002MFU

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

  54. REMOVE NO. 4 TRANSMISSION CLUTCH HUB


    1. A002NN2

      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. A002P8B

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

  56. REMOVE NO. 2 OUTPUT SHAFT FRONT BEARING


    1. A002P71E01

      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