OUTPUT SHAFT DISASSEMBLY

PROCEDURE


  1. INSPECT 1ST GEAR THRUST CLEARANCE

    Click here

  2. INSPECT 2ND GEAR THRUST CLEARANCE

    Click here

  3. INSPECT 3RD GEAR THRUST CLEARANCE

    Click here

  4. INSPECT 1ST GEAR RADIAL CLEARANCE

    Click here

  5. INSPECT 2ND GEAR RADIAL CLEARANCE

    Click here

  6. INSPECT 3RD GEAR RADIAL CLEARANCE

    Click here

  7. REMOVE 1ST GEAR


    1. A01LA9KN01

      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. A01L8GP

      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. A01LCP8N01

      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. A01LDZV

      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 shifting key and the 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. A01LFLWN01

      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 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 shifting keys and No. 2 shifting key springs from popping out.

  20. INSPECT OUTPUT SHAFT

    Click here

  21. INSPECT 3RD GEAR

    Click here

  22. INSPECT 2ND GEAR

    Click here

  23. INSPECT 1ST GEAR

    Click here

  24. INSPECT 1ST GEAR THRUST WASHER

    Click here

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

    Click here

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

    Click here

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

    Click here

  28. INSPECT REVERSE GEAR

    Click here

  29. INSPECT NO. 1 TRANSMISSION CLUTCH HUB

    Click here

  30. INSPECT NO. 2 TRANSMISSION HUB SLEEVE

    Click here

  31. INSPECT NO. 2 TRANSMISSION CLUTCH HUB

    Click here