OUTPUT SHAFT DISASSEMBLY


  1. INSPECT 3RD GEAR THRUST CLEARANCE

    A01567NE01

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

      Standard Clearance
      0.10 to 0.45 mm (0.00394 to 0.0177 in.)

      If the clearance is outside the specification, replace the defective gear, spacer or shaft.

  2. INSPECT 5TH GEAR THRUST CLEARANCE

    A01567NE03

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

      Standard Clearance
      0.10 to 0.35 mm (0.00394 to 0.0137 in.)

      If the clearance is outside the specification, replace the defective gear, spacer or shaft.

  3. INSPECT 2ND GEAR THRUST CLEARANCE

    A01567NE04

    1. Using a feeler gauge, measure the 2nd gear thrust clearance.

      Standard Clearance
      0.10 to 0.35 mm (0.00394 to 0.0137 in.)

      If the clearance is outside the specification, replace the defective gear, spacer or shaft.

  4. INSPECT 1ST GEAR THRUST CLEARANCE

    A01567NE05

    1. Using a feeler gauge, measure the 1st gear thrust clearance.

      Standard Clearance
      0.10 to 0.45 mm (0.00394 to 0.0177 in.)

      If the clearance is outside the specification, replace the defective gear, spacer or shaft.

  5. INSPECT 3RD GEAR RADIAL CLEARANCE

    A0155AB

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

      Standard Clearance
      0.020 to 0.073 mm (0.000788 to 0.00287 in.)

      If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.

  6. INSPECT 5TH GEAR RADIAL CLEARANCE

    A0158W7

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

      Standard Clearance
      0.015 to 0.068 mm (0.000591 to 0.00267 in.)

      If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.

  7. INSPECT 2ND GEAR RADIAL CLEARANCE

    A0156I5

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

      Standard Clearance
      0.015 to 0.068 mm (0.000591 to 0.00267 in.)

      If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.

  8. INSPECT 1ST GEAR RADIAL CLEARANCE

    A0155V7

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

      Standard Clearance
      0.020 to 0.073 mm (0.000788 to 0.00287 in.)

      If the clearance is outside the specification, replace the defective gear, needle roller bearing or shaft.

  9. REMOVE REVERSE GEAR SNAP RING

    A015AT4

    1. Using 2 screwdrivers and a hammer, tap out the snap ring.

      Tech Tips

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

  10. REMOVE 1ST GEAR

    A015E0M

    1. Shift the No. 1 transmission hub sleeve to the 2nd gear.

    2. A015E2DE01

      Using SST and a press, remove the bearing, 1st gear and synchronizer ring.

      SST
      09555-55010

  11. REMOVE 1ST GEAR NEEDLE ROLLER BEARING


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

  12. REMOVE NO. 1 SYNCHRONIZER RING SET


    1. Remove the No. 1 synchronizer ring from the 1st gear.

  13. REMOVE NO. 1 CLUTCH HUB SHAFT SNAP RING

    A0159O9

    1. Using 2 screwdrivers and a hammer, tap out the snap ring.

      Tech Tips

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

  14. REMOVE 2ND GEAR

    A01595T

    1. Using a press, remove the 2nd gear and synchronizer ring.

  15. REMOVE 2ND GEAR NEEDLE ROLLER BEARING


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

  16. REMOVE NO. 2 SYNCHRONIZER RING SET


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

  17. REMOVE NO. 1 TRANSMISSION HUB SLEEVE

    A015AHME07

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

      Tech Tips

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

  18. REMOVE NO. 2 CLUTCH HUB SETTING SHAFT SNAP RING

    A0156NC

    1. Using 2 screwdrivers and a hammer, tap out the snap ring.

      Tech Tips

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

  19. REMOVE 3RD GEAR

    A015C4S

    1. Shift the No. 3 transmission hub sleeve to the 5th gear.

    2. A0159FAE01

      Using SST and a press, remove the 3rd gear and synchronizer ring.

      SST
      09555-55010

  20. REMOVE 3RD GEAR NEEDLE ROLLER BEARING


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

  21. REMOVE NO. 3 SYNCHRONIZER RING SET


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

  22. REMOVE NO. 2 TRANSMISSION HUB SLEEVE

    A015AHME08

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

      Tech Tips

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

  23. REMOVE NO. 3 TRANSMISSION CLUTCH HUB SHAFT SNAP RING

    A0158Z8

    1. Using 2 screwdrivers and a hammer, tap out the snap ring.

      Tech Tips

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

  24. REMOVE 5TH GEAR

    A015BY9E01

    1. Using SST and a press, remove the 5th gear and synchronizer ring.

      SST
      09555-55010

  25. REMOVE 5TH COUNTER GEAR BEARING


    1. Remove the 5th counter gear bearing from the output shaft.

  26. REMOVE NO. 3 SYNCHRONIZER RING SET


    1. Remove the No. 3 synchronizer ring from the 5th gear.

  27. REMOVE NO. 3 TRANSMISSION HUB SLEEVE

    A015AHME09

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

      Tech Tips

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