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. A01GBNW

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

  10. REMOVE REAR OUTPUT SHAFT BEARING


    1. A01GAE9E01

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

      SST
      09201-31010
      09950-00020

  11. REMOVE 3RD DRIVEN GEAR


    1. A01GCHR

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

  12. REMOVE SPACER


    1. A01GDGF

      Remove the spacer from the No. 1 output shaft.

  13. REMOVE NEEDLE ROLLER BEARING


    1. A01GBOB

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

  14. REMOVE 3RD DRIVEN GEAR SYNCHRONIZER RING SET


    1. A01G9YX

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

  15. REMOVE SHAFT SNAP RING


    1. A01GBOP

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

      Note

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

  16. REMOVE 4TH DRIVEN GEAR


    1. A01GB4YE01

      Using SST and 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. A01GAOL

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

  18. REMOVE NO. 2 TRANSMISSION CLUTCH HUB


    1. A01GBDK

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

      Note

      Pay attention to prevent the balls and 3 synchromesh shifting key springs from scattering.

  19. REMOVE NEEDLE ROLLER BEARING


    1. A01GCIL

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

  20. REMOVE SPACER


    1. A01GBE8

      Remove the spacer from the No. 1 output shaft.

  21. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A01GCWQ

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

  22. REMOVE INNER 2ND GEAR BEARING RACE


    1. A01GCQC

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

  23. REMOVE 2ND DRIVEN GEAR


    1. A01GA3W

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

  24. REMOVE NEEDLE ROLLER BEARING


    1. A01GBYP

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

  25. REMOVE SYNCHROMESH SHIFTING KEY BALL


    1. A01GDGC

      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. A01GAS9

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

  27. REMOVE 1ST DRIVEN GEAR


    1. A01GCI6N01

      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. A01GANN

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

  29. REMOVE NO. 1 TRANSMISSION CLUTCH HUB


    1. A01GCA4

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

      Note

      Pay attention to prevent the balls and 3 synchromesh shifting key springs from scattering.

  30. REMOVE NEEDLE ROLLER BEARING


    1. A01GBNI

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

  31. REMOVE FRONT OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A01GA2D

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

  32. REMOVE FRONT OUTPUT SHAFT BEARING


    1. A01GAINE01

      Using SST and press, press out the front output shaft 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. A01GB4U

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

  40. REMOVE REAR NO. 2 OUTPUT SHAFT BEARING


    1. A01GCJ7E01

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

      SST
      09201-31010
      09950-00020

  41. REMOVE NEEDLE ROLLER BEARING


    1. A01GBRZ

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

  42. REMOVE SPACER


    1. A01GAOV

      Remove the spacer from the No. 2 output shaft.

  43. REMOVE 6TH GEAR SYNCHRONIZER RING


    1. A01GBZI

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

  44. REMOVE SHAFT SNAP RING


    1. A01GD46

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

      Note

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

  45. REMOVE 5TH DRIVEN GEAR


    1. A01GAYBE01

      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. A01GBM3

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

  47. REMOVE NO. 3 TRANSMISSION CLUTCH HUB


    1. A01GBQM

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

      Note

      Pay attention to prevent the balls and 3 synchromesh shifting key springs from scattering.

  48. REMOVE OUTPUT SHAFT COLLAR


    1. A01GC7X

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

  49. REMOVE 5TH GEAR NEEDLE ROLLER BEARING


    1. A01GBP9

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

  50. REMOVE 5TH GEAR BEARING SPACER


    1. A01GAY5

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

  51. REMOVE SHAFT SNAP RING


    1. A01GC6G

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

      Note

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

  52. REMOVE REVERSE DRIVEN GEAR


    1. A01GACQE01

      Using SST and 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. A01GD0P

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

  54. REMOVE NO. 4 TRANSMISSION CLUTCH HUB


    1. A01GBKUC04
      *1 No. 4 Transmission Clutch Hub
      *2 Shifting Key
      *3 Key Spring
      *4 No. 4 Transmission Hub Sleeve

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

  55. REMOVE NEEDLE ROLLER BEARING


    1. A01GC3G

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

  56. REMOVE NO. 2 OUTPUT SHAFT FRONT BEARING


    1. A01GC8HE01

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

      SST
      09201-31010
      09950-00020