OUTPUT SHAFT DISASSEMBLY


  1. INSPECT 1ST DRIVEN GEAR THRUST CLEARANCE


    1. A003DYN

      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. A003BKT

      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. A003AIM

      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. A003CGC

      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. A003DWS

      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. A003CP2

      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. A003BR8

      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. A003C5B

      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. A00E7BN

      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. A00E7VZE01

      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. A00EAN2

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

  12. REMOVE SPACER


    1. A00E960

      Remove the spacer from the No. 1 output shaft.

  13. REMOVE NEEDLE ROLLER BEARING


    1. A00E9TJ

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

  14. REMOVE 3RD DRIVEN GEAR SYNCHRONIZER RING SET


    1. A00E8HU

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

  15. REMOVE SHAFT SNAP RING


    1. A00EAU0

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

  16. REMOVE 4TH DRIVEN GEAR


    1. A00EAE1E01

      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. A00E9XP

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

  18. REMOVE NO. 2 TRANSMISSION CLUTCH HUB


    1. A00E8ZK

      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. A00E841

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

  20. REMOVE SPACER


    1. A00E9YD

      Remove the spacer from the No. 1 output shaft.

  21. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING


    1. A00E99C

      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. A00E9ZZ

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

  23. REMOVE 2ND DRIVEN GEAR


    1. A00E8LD

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

  24. REMOVE NEEDLE ROLLER BEARING


    1. A00E7P7

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

  25. REMOVE SYNCHROMESH SHIFTING KEY BALL


    1. A00E8W8E01
      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. A00E9GV

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

  27. REMOVE 1ST DRIVEN GEAR


    1. A00E9OEE01

      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. A00EB45

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

  29. REMOVE NO. 1 TRANSMISSION CLUTCH HUB


    1. A00E7PG

      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. A00E7X0

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

  31. REMOVE OUTPUT SHAFT FRONT BEARING SHAFT SNAP RING


    1. A00E85J

      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. A00E9I9E01

      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. A003E7J

      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. A003CQG

      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. A003DI1

      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. A003D8R

      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. A003DPB

      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. A003BXH

      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. A00EB3N

      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. A00E6ULE01

      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. A00E9VH

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

  42. REMOVE SPACER


    1. A00E7RI

      Remove the spacer from the No. 2 output shaft.

  43. REMOVE 6TH GEAR SYNCHRONIZER RING


    1. A00E7LM

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

  44. REMOVE SHAFT SNAP RING


    1. A00EBBO

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

  45. REMOVE 5TH DRIVEN GEAR


    1. A00EAJTE01

      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. A00E6T1

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

  47. REMOVE NO. 3 TRANSMISSION CLUTCH HUB


    1. A00E7DY

      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. A00E9X6

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

  49. REMOVE 5TH GEAR NEEDLE ROLLER BEARING


    1. A00EALT

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

  50. REMOVE 5TH GEAR BEARING SPACER


    1. A00EBEK

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

  51. REMOVE SHAFT SNAP RING


    1. A00E6SJ

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

  52. REMOVE REVERSE DRIVEN GEAR


    1. A00EAD3E01

      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. A00E9EN

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

  54. REMOVE NO. 4 TRANSMISSION CLUTCH HUB


    1. A00EBDE

      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. A00EASB

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

  56. REMOVE NO. 2 OUTPUT SHAFT FRONT BEARING


    1. A00E7TBE01

      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