OUTPUT SHAFT DISASSEMBLY


  1. INSPECT 1ST GEAR THRUST CLEARANCE


    1. A005TYC

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

      Standard clearance
      0.23 to 0.37 mm (0.00905 to 0.0146 in.)
      Maximum clearance
      0.37 mm (0.0146 in.)

      If the clearance is more than the maximum, replace the No. 1 transmission clutch hub, 1st gear bush or 1st gear. Replace the part or parts determined to be the most likely cause of the problem.

  2. INSPECT 2ND GEAR THRUST CLEARANCE


    1. A005UQJ

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

      Standard clearance
      0.16 to 0.33 mm (0.00629 to 0.0130 in.)
      Maximum clearance
      0.33 mm (0.0130 in.)

      If the clearance is more than the maximum, replace the inner 2nd gear bearing race, No. 1 transmission clutch hub, 2nd gear or 3rd driven gear. Replace the part or parts determined to be the most likely cause of the problem.

  3. INSPECT 1ST GEAR RADIAL CLEARANCE


    1. A005VQX

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

      Standard clearance
      0.009 to 0.047 mm (0.000354 to 0.00185 in.)
      Maximum clearance
      0.047 mm (0.00185 in.)

      If the clearance is more than the maximum, replace the 1st gear, 1st 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 GEAR RADIAL CLEARANCE


    1. A005U02

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

      Standard clearance
      0.009 to 0.047 mm (0.000354 to 0.00185 in.)
      Maximum clearance
      0.047 mm (0.00185 in.)

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

  5. REMOVE 6TH DRIVEN GEAR


    1. A00D8TPE01

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

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04010, 09955-04021, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00180, 09951-00270, 09952-06010 )

  6. REMOVE OUTPUT GEAR SPACER


    1. A00D3TB

      Remove the output gear spacer from the output shaft.

  7. REMOVE 4TH DRIVEN GEAR


    1. A00D8RJE01

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

      SST
      09527-10011
      09950-40011   ( 09957-04010 )
      09950-60010   ( 09951-00180, 09951-00270, 09952-06010 )

      Note

      Support the output shaft by hand to prevent it from falling.

  8. REMOVE OUTPUT GEAR SPACER


    1. A00D4OO

      Remove the output gear spacer from the output shaft.

  9. REMOVE 2ND GEAR


    1. A00D761E01

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

      SST
      09950-40011   ( 09951-04010, 09952-04010, 09953-04020, 09954-04030, 09955-04021, 09957-04010, 09958-04011 )
      09950-60010   ( 09951-00180, 09951-00270, 09952-06010 )

  10. REMOVE 2ND GEAR NEEDLE ROLLER BEARING


    1. A00D5UD

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

  11. REMOVE INNER 2ND GEAR BEARING RACE


    1. A00D5VH

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

  12. REMOVE NO. 1 SYNCHRONIZER RING SET (for 2nd Gear)


    1. A00D79A

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

  13. REMOVE REVERSE GEAR


    1. A00D8MOE01

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

  14. REMOVE NO. 1 SYNCHROMESH SHIFTING KEY


    1. A00D8TX

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

  15. REMOVE NO. 1 TRANSMISSION CLUTCH HUB


    1. A00D5HX

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

  16. REMOVE NO. 1 SYNCHRONIZER RING SET (for 1st Gear)


    1. A00D83L

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

  17. REMOVE 1ST GEAR


    1. A00D52A

      Remove the 1st gear from the output shaft.

  18. REMOVE 1ST GEAR NEEDLE ROLLER BEARING


    1. A00D8MS

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

  19. REMOVE 1ST GEAR BUSH


    1. A00D7WY

      Remove the 1st gear bush from the output shaft.

  20. REMOVE FRONT OUTPUT SHAFT BEARING


    1. A00D93BE01

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

      SST
      09950-00020
      09950-00030
      09950-40011   ( 09957-04010 )
      09950-60010   ( 09951-00180, 09951-00340, 09952-06010 )