OUTPUT SHAFT DISASSEMBLY


  1. INSPECT 5TH GEAR THRUST CLEARANCE


    1. A00K1FRE01
      Text in Illustration
      *1 5th Gear

      Using a dial indicator, measure the thrust clearance.

      Standard clearance
      0.10 to 0.30 mm (0.00394 to 0.0118 in.)

      • If the result is not as specified, replace the 5th gear.

  2. INSPECT 1ST GEAR THRUST CLEARANCE


    1. A00JU7KE01
      Text in Illustration
      *1 1st Gear

      Using a dial indicator, measure the thrust clearance.

      Standard clearance
      0.10 to 0.25 mm (0.00394 to 0.00984 in.)

      • If the result is not as specified, replace the No. 1 synchronizer ring set.

  3. INSPECT 2ND GEAR THRUST CLEARANCE


    1. A00JZZZE01
      Text in Illustration
      *1 2nd Gear

      Using a dial indicator, measure the thrust clearance.

      Standard clearance
      0.10 to 0.25 mm (0.00394 to 0.00984 in.)

      • If the result is not as specified, replace the No. 1 synchronizer ring set.

  4. INSPECT 3RD GEAR THRUST CLEARANCE


    1. A00JTTCE03
      Text in Illustration
      *1 3rd Gear

      Using a feeler gauge, measure the thrust clearance.

      Standard clearance
      0.10 to 0.25 mm (0.00394 to 0.00984 in.)

      • If the result is not as specified, replace the No. 2 synchronizer ring set.

  5. INSPECT 1ST GEAR RADIAL CLEARANCE


    1. A00JW6QE01

      Using a dial indicator, measure the radial clearance.

      Standard clearance
      0.009 to 0.056 mm (0.000355 to 0.00220 in.)

      • If the result is not as specified, replace the 1st gear needle roller bearing.

  6. INSPECT 2ND GEAR RADIAL CLEARANCE


    1. A00JV2TE01

      Using a dial indicator, measure the radial clearance.

      Standard clearance
      0.008 to 0.034 mm (0.000315 to 0.00133 in.)

      • If the result is not as specified, replace the 2nd gear needle roller bearing.

  7. INSPECT 3RD GEAR RADIAL CLEARANCE


    1. A00K0DQE01

      Using a dial indicator, measure the radial clearance.

      Standard clearance
      0.008 to 0.034 mm (0.000315 to 0.00133 in.)

      • If the result is not as specified, replace the 3rd gear needle roller bearing.

  8. REMOVE 1ST GEAR


    1. A00JXC7E01

      Using 2 screwdrivers and a hammer, tap off the snap ring from the output shaft.

    2. A00K0SME01

      Using SST and a press, remove the 5th gear, center bearing, 1st gear bearing inner race, 1st gear and 1st gear needle roller bearing from the output shaft.

      SST
      09527-10011

  9. REMOVE NO. 1 SYNCHRONIZER RING (for 1st Gear)


    1. Remove the No. 1 synchronizer ring from the No. 1 clutch hub.

  10. REMOVE 1ST GEAR BEARING INNER RACE LOCK BALL


    1. A00JUTSE01

      Using a magnet hand, remove the lock ball.

  11. REMOVE 2ND GEAR


    1. A00K0ECE01

      Using SST and a press, remove the reverse gear, No. 1 transmission clutch hub, No. 1 synchronizer ring and 2nd gear.

      SST
      09950-00020

  12. REMOVE NO. 2 SYNCHRONIZER RING (for 2nd Gear)


    1. A00JYWTE01

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

  13. REMOVE 2ND GEAR NEEDLE ROLLER BEARING


    1. A00JVO7E01

      Remove the needle roller bearing from the output shaft.

  14. REMOVE NO. 1 TRANSMISSION CLUTCH HUB


    1. A00K0J0E02
      Text in Illustration
      *1 No. 1 Synchromesh Shifting Key Spring
      *2 Reverse Gear
      *3 No. 1 Synchromesh Shifting Key
      *4 No. 1 Transmission Clutch Hub

      Remove the 2 synchromesh shifting key springs.

    2. Remove the reverse gear and 3 synchromesh shifting keys from the transmission clutch hub.

  15. REMOVE 3RD GEAR


    1. A00JULPE04

      Using a snap ring expander, remove the snap ring from the output shaft.

    2. A00JX4AE01

      Using a press, remove the No. 2 transmission clutch hub and 3rd gear.

  16. REMOVE NO. 1 SYNCHRONIZER RING


    1. A00K0Y3

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

  17. REMOVE 3RD GEAR NEEDLE ROLLER BEARING


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

  18. REMOVE NO. 2 TRANSMISSION CLUTCH HUB


    1. A00JUTUE02
      Text in Illustration
      *1 No. 2 Synchromesh Shifting Key Spring
      *2 No. 2 Transmission Hub Sleeve
      *3 No. 2 Synchromesh Shifting Key
      *4 No. 2 Transmission Clutch Hub

      Remove the 2 synchromesh shifting key springs.

    2. Remove the transmission hub sleeve and 3 synchromesh shifting keys from the transmission clutch hub.