OUTPUT SHAFT DISASSEMBLY


  1. INSPECT 1ST GEAR THRUST CLEARANCE


    1. A011B0E

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

      Standard clearance
      0.20 to 0.38 mm (0.00787 to 0.0150 in.)
      Maximum clearance
      0.38 mm (0.0150 in.)

      If the clearance exceeds the maximum, replace the No. 1 transmission clutch hub, 1st gear bush or 1st gear.

  2. INSPECT 2ND GEAR THRUST CLEARANCE


    1. A0118CR

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

      Standard clearance
      0.15 to 0.33 mm (0.00591 to 0.0130 in.)
      Maximum clearance
      0.33 mm (0.0130 in.)

      If the clearance exceeds the maximum, replace the inner 2nd gear bearing race, No. 1 transmission clutch hub, 2nd gear or 3rd driven gear.

  3. INSPECT 1ST GEAR RADIAL CLEARANCE


    1. A0119JE

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

      Standard clearance
      0.009 to 0.077 mm (0.000354 to 0.00303 in.)
      Maximum clearance
      0.077 mm (0.00303 in.)

      If the clearance exceeds the maximum, replace the 1st gear, 1st gear needle roller bearing or output shaft.

  4. INSPECT 2ND GEAR RADIAL CLEARANCE


    1. A0118I9

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

      Standard clearance
      0.009 to 0.077 mm (0.000354 to 0.00303 in.)
      Maximum clearance
      0.077 mm (0.00303 in.)

      If the clearance exceeds the maximum, replace the 2nd gear, 2nd gear needle roller bearing or output shaft.

  5. REMOVE 6TH DRIVEN GEAR


    1. A011910E01

      Using SST and a press, remove the rear output shaft bearing and 6th driven gear from the output shaft.

      SST
      09527-21011
      09950-60010   ( 09951-00290 )
      09950-70010   ( 09951-07100 )

      Note

      Support the output shaft by hand to prevent it from dropping off.

  6. REMOVE OUTPUT GEAR SPACER


    1. A0118RXE01

      Remove the output gear spacer from the output shaft.

  7. REMOVE 4TH DRIVEN GEAR


    1. A011847E01

      Using SST and a press, remove the 5th driven gear and 4th driven gear from the output shaft.

      SST
      09527-21011
      09950-60010   ( 09951-00290 )

      Note

      Support the output shaft by hand to prevent it from dropping off.

  8. REMOVE OUTPUT GEAR SPACER


    1. A011BTFE01

      Remove the output gear spacer from the output shaft.

  9. REMOVE 2ND GEAR


    1. A011AZAE01

      Using SST and a press, remove the 3rd driven gear with the 2nd gear from the output shaft.

      SST
      09950-00020
      09950-60010   ( 09951-00290 )

      Note


      • Do not tighten SST excessively.

      • Support the output shaft by hand to prevent it from dropping off.

  10. REMOVE 2ND GEAR NEEDLE ROLLER BEARING


    1. A011AZDE01

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

  11. REMOVE INNER 2ND GEAR BEARING RACE


    1. A0119DGE01

      Remove the inner 2nd gear bearing race from the output shaft.

  12. REMOVE NO. 1 SYNCHRONIZER RING SET (FOR 2ND GEAR)


    1. A0119CR

      Remove the No. 1 synchronizer ring set from the reverse gear.

  13. REMOVE REVERSE GEAR


    1. A0117YRE01

      Remove the reverse gear from the No. 1 transmission clutch hub.

  14. REMOVE NO. 1 SYNCHROMESH SHIFTING KEY


    1. A011AF7

      Remove the 3 No. 1 synchromesh shifting keys from the No. 1 transmission clutch hub.

  15. REMOVE NO. 1 TRANSMISSION CLUTCH HUB


    1. A01186F

      Remove the No. 1 transmission clutch hub from the output shaft.

  16. REMOVE NO. 1 SYNCHRONIZER RING SET (FOR 1ST GEAR)


    1. A01171E

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

  17. REMOVE 1ST GEAR


    1. A0117QS

      Remove the 1st gear from the output shaft.

  18. REMOVE 1ST GEAR NEEDLE ROLLER BEARING


    1. A0118BL

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

  19. REMOVE 1ST GEAR BUSH


    1. A0118DQ

      Remove the 1st gear bush from the output shaft.

  20. REMOVE FRONT OUTPUT SHAFT BEARING


    1. A01170SE01

      Using SST and a press, remove the front output shaft bearing from the output shaft.

      SST
      09950-00020
      09950-60010   ( 09951-00290 )
      09950-70010   ( 09951-07100 )

      Note


      • Do not tighten SST excessively.

      • Support the output shaft by hand to prevent it from dropping off.