OUTPUT SHAFT DISASSEMBLY


  1. INSPECT 1ST GEAR THRUST CLEARANCE


    1. A005TYC

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

      Standard clearance
      0.20 to 0.38 mm (0.00788 to 0.0149 in.)
      Maximum clearance
      0.38 mm (0.0149 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
      0.15 to 0.33 mm (0.00591 to 0.0129 in.)
      Maximum clearance
      0.33 mm (0.0129 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
      for TMC Made
      0.009 to 0.077 mm (0.000355 to 0.00303 in.)
      except TMC Made
      0.009 to 0.075 mm (0.000355 to 0.00295 in.)
      Maximum clearance
      for TMC Made
      0.077 mm (0.00303 in.)
      except TMC Made
      0.075 mm (0.00295 in.)

      Tech Tips

      Two different manual transaxle models produced by different manufacturers are available for this vehicle.

      Referring to the Introduction section, check the serial number. Confirm which manufacturer produced the manual transaxle according to the following table.

      Serial Number Manufacturer
      ##JTR############ for TMC Made
      ##EPP############ except TMC Made

      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
      for TMC Made
      0.009 to 0.077 mm (0.000355 to 0.00303 in.)
      except TMC Made
      0.009 to 0.075 mm (0.000355 to 0.00295 in.)
      Maximum clearance
      for TMC Made
      0.077 mm (0.00303 in.)
      except TMC Made
      0.075 mm (0.00295 in.)

      Tech Tips

      Two different manual transaxle models produced by different manufacturers are available for this vehicle.

      Referring to the Introduction section, check the serial number. Confirm which manufacturer produced the manual transaxle according to the following table.

      Serial Number Manufacturer
      ##JTR############ for TMC Made
      ##EPP############ except TMC Made

      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. A00DU3OE01

      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 falling.

  6. REMOVE OUTPUT GEAR SPACER


    1. A00DSCFE01

      Remove the output gear spacer from the output shaft.

  7. REMOVE 4TH DRIVEN GEAR


    1. A00DPM7E01

      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 falling.

  8. REMOVE OUTPUT GEAR SPACER


    1. A00DRFVE01

      Remove the output gear spacer from the output shaft.

  9. REMOVE 2ND GEAR


    1. A00DUONE01

      Using SST and a press, remove the 3rd driven gear and 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 falling.

  10. REMOVE 2ND GEAR NEEDLE ROLLER BEARING


    1. A00DQR2E01

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

  11. REMOVE INNER 2ND GEAR BEARING RACE


    1. A00DRNSE01

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

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


    1. A00DRVL

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

  13. REMOVE REVERSE GEAR


    1. A00DR5LE01

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

  14. REMOVE NO. 1 SYNCHROMESH SHIFTING KEY


    1. A00DS36

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

  15. REMOVE NO. 1 TRANSMISSION CLUTCH HUB


    1. A00DRLO

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

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


    1. A00DS6M

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

  17. REMOVE 1ST GEAR


    1. A00DQX6

      Remove the 1st gear from the output shaft.

  18. REMOVE 1ST GEAR NEEDLE ROLLER BEARING


    1. A00DPVR

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

  19. REMOVE 1ST GEAR BUSH


    1. A00DSDE

      Remove the 1st gear bush from the output shaft.

  20. REMOVE FRONT OUTPUT SHAFT BEARING


    1. A00DUBBE01

      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 falling.