OUTPUT SHAFT DISASSEMBLY

PROCEDURE


  1. INSPECT 1ST GEAR THRUST CLEARANCE

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  2. INSPECT 2ND GEAR THRUST CLEARANCE

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  3. INSPECT 3RD GEAR THRUST CLEARANCE

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  4. INSPECT 1ST GEAR RADIAL CLEARANCE

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  5. INSPECT 2ND GEAR RADIAL CLEARANCE

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  6. INSPECT 3RD GEAR RADIAL CLEARANCE

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  7. REMOVE 1ST GEAR


    1. B003N8CN01

      Using SST and a press, pull off the 5th gear, output shaft center bearing, 1st gear thrust washer and 1st gear from the output shaft.

      SST
      09950-00020

  8. REMOVE NO. 1 SYNCHRONIZER RING SET (FOR 1ST GEAR)


    1. Remove the No. 1 synchronizer ring set (for 1st gear) from the output shaft.

  9. REMOVE 1ST GEAR THRUST WASHER PIN


    1. Remove the 1st gear thrust washer pin from the output shaft.

  10. REMOVE 1ST GEAR NEEDLE ROLLER BEARING


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

  11. REMOVE 1ST GEAR BEARING SPACER


    1. Remove the 1st gear bearing spacer from the output shaft.

  12. REMOVE BEARING SHAFT SNAP RING


    1. B003PKG

      Using 2 screwdrivers and a hammer, remove the bearing shaft snap ring from the output shaft.

      Note

      Use a cloth to prevent the bearing shaft snap ring from flying off.

  13. REMOVE 2ND GEAR


    1. B003NN0N01

      Using SST and a press, pull out the No. 1 transmission clutch hub together with the reverse gear, No. 1 synchronizer ring set (for 2nd gear) and 2nd gear from the output shaft.

      SST
      09950-00020

  14. REMOVE 2ND GEAR NEEDLE ROLLER BEARING


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

  15. REMOVE REVERSE GEAR


    1. B003NVI

      Remove the reverse gear, 3 No. 1 synchromesh shifting keys and 3 No. 1 synchromesh shifting key springs.

      Note

      Use a cloth to prevent the No. 1 synchromesh shifting keys and No. 1 synchromesh shifting key springs from popping out.

  16. REMOVE CLUTCH HUB SET SHAFT SNAP RING


    1. Using a snap ring expander, remove the clutch hub set shaft snap ring from the output shaft.

  17. REMOVE 3RD GEAR


    1. B003M8IN01

      Using SST and a press, pull out the No. 2 transmission clutch hub together with the No. 2 transmission hub sleeve, No. 2 synchronizer ring set and 3rd gear from the output shaft.

      SST
      09950-00020

  18. REMOVE 3RD GEAR NEEDLE ROLLER BEARING


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

  19. REMOVE NO. 2 TRANSMISSION HUB SLEEVE


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

      Note

      Use a cloth to prevent the No. 2 synchromesh shifting keys and No. 2 synchromesh shifting key springs from popping out.

  20. INSPECT OUTPUT SHAFT

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  21. INSPECT 3RD GEAR

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  22. INSPECT 2ND GEAR

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  23. INSPECT 1ST GEAR

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  24. INSPECT 1ST GEAR THRUST WASHER

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  25. INSPECT NO. 1 SYNCHRONIZER RING SET (FOR 1ST GEAR)

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  26. INSPECT NO. 1 SYNCHRONIZER RING SET (FOR 2ND GEAR)

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  27. INSPECT NO. 2 SYNCHRONIZER RING SET (FOR 3RD GEAR)

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  28. INSPECT REVERSE GEAR

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  29. INSPECT NO. 1 TRANSMISSION CLUTCH HUB

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  30. INSPECT NO. 2 TRANSMISSION HUB SLEEVE

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  31. INSPECT NO. 2 TRANSMISSION CLUTCH HUB

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