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. A00Y7PI

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

  10. REMOVE OUTPUT SHAFT REAR BEARING


    1. A00Y575N01

      Using SST and a press, remove the output shaft rear bearing from the No. 1 output shaft.

      SST
      09201-31010
      09950-00020

  11. REMOVE 3RD DRIVEN GEAR


    1. A00YBEG

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

  12. REMOVE SPACER


    1. A00Y6BF

      Remove the spacer from the No. 1 output shaft.

  13. REMOVE NEEDLE ROLLER BEARING


    1. A00Y780

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

  14. REMOVE 3RD DRIVEN GEAR SYNCHRONIZER RING SET


    1. A00Y64M

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

  15. REMOVE SHAFT SNAP RING


    1. A00Y967

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

  16. REMOVE 4TH DRIVEN GEAR


    1. A00Y88XN01

      Using SST and a press, remove 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. A00YB58

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

  18. REMOVE NO. 2 TRANSMISSION CLUTCH HUB


    1. A00YA5E

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

      Note

      Pay attention to prevent the balls and synchronizer shifting key springs from scattering.

  19. REMOVE NEEDLE ROLLER BEARING


    1. A00Y90B

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

  20. REMOVE SPACER


    1. A00Y7JS

      Remove the spacer from the No. 1 output shaft.

  21. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A00YAN3

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

  22. REMOVE 2ND DRIVEN GEAR BEARING INNER RACE


    1. A00YABI

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

  23. REMOVE 2ND DRIVEN GEAR


    1. A00Y9GS

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

  24. REMOVE NEEDLE ROLLER BEARING


    1. A00Y6XA

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

  25. REMOVE SYNCHROMESH SHIFTING KEY BALL


    1. A00Y7G7C01
      *a 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. A00Y9X4

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

  27. REMOVE 1ST DRIVEN GEAR


    1. A00YBCEN01

      Using SST and a press, remove 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. A00Y6CD

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

  29. REMOVE NO. 1 TRANSMISSION CLUTCH HUB


    1. A00Y6Y9

      Remove the No. 1 transmission clutch hub, 3 No. 1 synchromesh shifting keys, 3 balls and 3 synchronizer shifting key springs from the No. 1 transmission hub sleeve.

      Note

      Pay attention to prevent the balls and synchronizer shifting key springs from scattering.

  30. REMOVE NEEDLE ROLLER BEARING


    1. A00Y6ZR

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

  31. REMOVE OUTPUT SHAFT FRONT BEARING SHAFT SNAP RING


    1. A00YA5J

      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 INNER RACE


    1. A00YAIQN01

      Using SST and a press, remove the output shaft front bearing inner race 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. A00Y8EZ

      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. A00YAEON01

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

      SST
      09201-31010
      09950-00020

  41. REMOVE NEEDLE ROLLER BEARING


    1. A00Y6QA

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

  42. REMOVE SPACER


    1. A00Y73H

      Remove the spacer from the No. 2 output shaft.

  43. REMOVE 6TH DRIVEN GEAR SYNCHRONIZER RING


    1. A00Y8W0

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

  44. REMOVE SHAFT SNAP RING


    1. A00Y996

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

  45. REMOVE 5TH DRIVEN GEAR


    1. A00YAXPN01

      Using SST and a press, remove the No. 3 transmission hub sleeve, 5th driving gear synchronizer ring, 5th driven gear, 2 spacers and needle roller bearing from the No. 2 output shaft.

      SST
      09950-00020

  46. REMOVE 5TH DRIVEN GEAR SYNCHRONIZER RING


    1. A00Y8YJ

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

  47. REMOVE NO. 3 TRANSMISSION CLUTCH HUB


    1. A00Y7E3

      Remove the No. 3 transmission clutch hub, 3 No. 1 synchromesh shifting keys, 3 ball and 3 synchronizer shifting key springs from the No. 3 transmission hub sleeve.

      Note

      Pay attention to prevent the balls and synchronizer shifting key springs from scattering.

  48. REMOVE SHAFT SNAP RING


    1. A00Y5PF

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

  49. REMOVE REVERSE DRIVEN GEAR


    1. A00Y5IVN01

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

      SST
      09950-00020

  50. REMOVE REVERSE DRIVEN GEAR SYNCHRONIZER RING


    1. A00Y5JK

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

  51. REMOVE NO. 4 TRANSMISSION CLUTCH HUB


    1. A00Y56AC03
      *1 Hub Sleeve
      *2 Shifting Key
      *3 Key Spring
      *4 No. 4 Transmission Clutch Hub

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

  52. REMOVE NEEDLE ROLLER BEARING


    1. A00Y8L9

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

  53. REMOVE NO. 2 OUTPUT SHAFT FRONT BEARING


    1. A00Y5FCN01

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

      SST
      09201-31010
      09950-00020