ВЫХОДНОЙ ВАЛ РАЗБОРКА


  1. INSPECT 1ST DRIVEN GEAR THRUST CLEARANCE


    1. A01INLE

      Using a dial indicator, measure the 1st driven gear thrust clearance.

      Standard clearance
      0.10 to 0.35 mm (0.00394 to 0.0137 in.)
      Maximum clearance
      0.35 mm (0.0137 in.)

      If the clearance is more than the maximum, replace the 1st driven gear, needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  2. INSPECT 1ST DRIVEN GEAR RADIAL CLEARANCE


    1. A01IREI

      Using a dial indicator, measure the 1st driven gear radial clearance.

      Standard clearance
      0.015 to 0.068 mm (0.000591 to 0.00267 in.)
      Maximum clearance
      0.068 mm (0.00267 in.)

      If the clearance is more than the maximum, replace the 1st driven gear, needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  3. INSPECT 2ND DRIVEN GEAR THRUST CLEARANCE


    1. A01ISIT

      Using a dial indicator, measure the 2nd driven gear thrust clearance.

      Standard clearance
      0.11 to 0.46 mm (0.00434 to 0.0181 in.)
      Maximum clearance
      0.46 mm (0.0181 in.)

      If the clearance is more than the maximum, replace the 2nd driven gear, needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  4. INSPECT 2ND DRIVEN GEAR RADIAL CLEARANCE


    1. A01IQUG

      Using a dial indicator, measure the 2nd driven gear radial clearance.

      Standard clearance
      0.015 to 0.048 mm (0.000591 to 0.00188 in.)
      Maximum clearance
      0.048 mm (0.00188 in.)

      If the clearance is more than the maximum, replace the 2nd driven gear, needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  5. INSPECT 3RD DRIVEN GEAR THRUST CLEARANCE


    1. A01IUKC

      Using a feeler gauge, measure the 3rd driven gear thrust clearance.

      Standard clearance
      0.11 to 0.54 mm (0.00434 to 0.0212 in.)
      Maximum clearance
      0.54 mm (0.0212 in.)

      If the clearance is more than the maximum, replace the 3rd driven gear, needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  6. INSPECT 3RD DRIVEN GEAR RADIAL CLEARANCE


    1. A01IUBD

      Using a dial indicator, measure the 3rd driven gear radial clearance.

      Standard clearance
      0.015 to 0.066 mm (0.000591 to 0.00259 in.)
      Maximum clearance
      0.066 mm (0.00259 in.)

      If the clearance is more than the maximum, replace the 3rd driven gear, needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  7. INSPECT 4TH DRIVEN GEAR THRUST CLEARANCE


    1. A01IQRL

      Using a feeler gauge, measure the 4th driven gear thrust clearance.

      Standard clearance
      0.10 to 0.65 mm (0.00394 to 0.0255 in.)
      Maximum clearance
      0.65 mm (0.0255 in.)

      If the clearance is more than the maximum, replace the 4th driven gear, needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  8. INSPECT 4TH DRIVEN GEAR RADIAL CLEARANCE


    1. A01INXO

      Using a dial indicator, measure the 4th driven gear radial clearance.

      Standard clearance
      0.015 to 0.066 mm (0.000591 to 0.00259 in.)
      Maximum clearance
      0.066 mm (0.00259 in.)

      If the clearance is more than the maximum, replace the 4th driven gear, needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  9. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A01IPCM

      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. A01IPTJE01

      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. A01IQDI

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

  12. REMOVE SPACER


    1. A01INQT

      Remove the spacer from the No. 1 output shaft.

  13. REMOVE NEEDLE ROLLER BEARING


    1. A01INWV

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

  14. REMOVE 3RD DRIVEN GEAR SYNCHRONIZER RING SET


    1. A01IQZ2

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

  15. REMOVE SHAFT SNAP RING


    1. A01IPOA

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

  16. REMOVE 4TH DRIVEN GEAR


    1. A01IQUWE01

      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. A01IR2O

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

  18. REMOVE NO. 2 TRANSMISSION CLUTCH HUB


    1. A01IQ0C

      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. A01IUBN

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

  20. REMOVE SPACER


    1. A01ITK9

      Remove the spacer from the No. 1 output shaft.

  21. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A01IRWA

      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. A01IO6T

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

  23. REMOVE 2ND DRIVEN GEAR


    1. A01IR2Z

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

  24. REMOVE NEEDLE ROLLER BEARING


    1. A01IPCS

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

  25. REMOVE SYNCHROMESH SHIFTING KEY BALL


    1. A01IOFPE01
      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. A01INPD

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

  27. REMOVE 1ST DRIVEN GEAR


    1. A01IR4ZE01

      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. A01IT5S

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

  29. REMOVE NO. 1 TRANSMISSION CLUTCH HUB


    1. A01IPWB

      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. A01ITG1

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

  31. REMOVE OUTPUT SHAFT FRONT BEARING SHAFT SNAP RING


    1. A01IMZE

      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. A01IQDHE01

      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


    1. A01ISLY

      Using a feeler gauge, measure the 5th driven gear thrust clearance.

      Standard clearance
      0.10 to 0.55 mm (0.00394 to 0.0216 in.)
      Maximum clearance
      0.55 mm (0.0216 in.)

      If the clearance is more than the maximum, replace the 5th driven gear, needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  34. INSPECT 5TH DRIVEN GEAR RADIAL CLEARANCE


    1. A01IRZH

      Using a dial indicator, measure the 5th driven gear radial clearance.

      Standard clearance
      0.015 to 0.066 mm (0.000591 to 0.00259 in.)
      Maximum clearance
      0.066 mm (0.00259 in.)

      If the clearance is more than the maximum, replace the 5th driven gear, needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  35. INSPECT 6TH DRIVEN GEAR THRUST CLEARANCE


    1. A01IP5U

      Using a feeler gauge, measure the 6th driven gear thrust clearance.

      Standard clearance
      0.10 to 0.55 mm (0.00394 to 0.0216 in.)
      Maximum clearance
      0.55 mm (0.0216 in.)

      If the clearance is more than the maximum, replace the 6th driven gear, needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  36. INSPECT 6TH DRIVEN GEAR RADIAL CLEARANCE


    1. A01IQNH

      Using a dial indicator, measure the 6th driven gear radial clearance.

      Standard clearance
      0.015 to 0.066 mm (0.000591 to 0.00259 in.)
      Maximum clearance
      0.066 mm (0.00259 in.)

      If the clearance is more than the maximum, replace the 6th driven gear, needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  37. INSPECT REVERSE DRIVEN GEAR THRUST CLEARANCE


    1. A01IU4B

      Using a feeler gauge, measure the reverse driven gear thrust clearance.

      Standard clearance
      0.11 to 0.34 mm (0.00434 to 0.0133 in.)
      Maximum clearance
      0.34 mm (0.0133 in.)

      If the clearance is more than the maximum, replace the reverse driven gear, needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  38. INSPECT REVERSE DRIVEN GEAR RADIAL CLEARANCE


    1. A01IPV6

      Using a dial indicator, measure the reverse driven gear radial clearance.

      Standard clearance
      0.015 to 0.068 mm (0.000591 to 0.00267 in.)
      Maximum clearance
      0.068 mm (0.00267 in.)

      If the clearance is more than the maximum, replace the reverse driven gear, needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  39. REMOVE NO. 2 OUTPUT SHAFT BEARING SNAP RING


    1. A01IU05

      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. A01INJ4E01

      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. A01IN2D

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

  42. REMOVE SPACER


    1. A01ITJV

      Remove the spacer from the No. 2 output shaft.

  43. REMOVE 6TH GEAR SYNCHRONIZER RING


    1. A01IP8T

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

  44. REMOVE SHAFT SNAP RING


    1. A01INT4

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

  45. REMOVE 5TH DRIVEN GEAR


    1. A01IPOZE01

      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. A01INU4

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

  47. REMOVE NO. 3 TRANSMISSION CLUTCH HUB


    1. A01ISJ3

      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. A01IPEJ

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

  49. REMOVE 5TH GEAR NEEDLE ROLLER BEARING


    1. A01ITB9

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

  50. REMOVE 5TH GEAR BEARING SPACER


    1. A01ITJK

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

  51. REMOVE SHAFT SNAP RING


    1. A01IO6I

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

  52. REMOVE REVERSE DRIVEN GEAR


    1. A01IT2YE01

      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. A01IT9R

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

  54. REMOVE NO. 4 TRANSMISSION CLUTCH HUB


    1. A01IQLG

      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. A01IQJV

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

  56. REMOVE NO. 2 OUTPUT SHAFT FRONT BEARING


    1. A01ITIRE01

      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