OUTPUT SHAFT DISASSEMBLY

PROCEDURE

  1. INSPECT 1ST DRIVEN GEAR THRUST CLEARANCE

    Click here

  2. INSPECT 1ST DRIVEN GEAR RADIAL CLEARANCE

    Click here

  3. INSPECT 2ND DRIVEN GEAR THRUST CLEARANCE

    Click here

  4. INSPECT 2ND DRIVEN GEAR RADIAL CLEARANCE

    Click here

  5. INSPECT 3RD DRIVEN GEAR THRUST CLEARANCE

    Click here

  6. INSPECT 3RD DRIVEN GEAR RADIAL CLEARANCE

    Click here

  7. INSPECT 4TH DRIVEN GEAR THRUST CLEARANCE

    Click here

  8. INSPECT 4TH DRIVEN GEAR RADIAL CLEARANCE

    Click here

  9. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING

    1. C112408

      Using a snap ring expander, remove the output shaft bearing shaft snap ring from the No. 1 output shaft.

  10. REMOVE REAR OUTPUT SHAFT BEARING

    1. C112409E01

      Using SST and press, press out the rear output shaft bearing from the No. 1 output shaft.

      09201-31010

      09950-00020

  11. REMOVE 3RD DRIVEN GEAR

    1. C112410

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

  12. REMOVE SPACER

    1. C112411

      Remove the spacer from the No. 1 output shaft.

  13. REMOVE 3RD GEAR NEEDLE ROLLER BEARING

    1. C112412

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

  14. REMOVE 3RD DRIVEN GEAR SYNCHRONIZER RING SET

    1. C112413

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

  15. REMOVE SHAFT SNAP RING

    1. C112414

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

      Note:

      Use a piece of cloth to prevent the snap ring from flying off.

  16. REMOVE 4TH DRIVEN GEAR

    1. C133415E01

      Using SST and 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.

      09950-00020

  17. REMOVE 4TH DRIVEN GEAR SYNCHRONIZER RING SET

    1. C117924

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

  18. REMOVE NO. 2 TRANSMISSION CLUTCH HUB

    1. C277781

      Remove the No. 2 transmission clutch hub, 3 No. 1 synchromesh shifting keys, 3 balls and 3 synchromesh shifting key springs from the No. 2 transmission hub sleeve.

      Note:

      Pay attention to prevent the balls and 3 synchromesh shifting key springs from scattering.

  19. REMOVE NEEDLE ROLLER BEARING

    1. C112416

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

  20. REMOVE SPACER

    1. C112417

      Remove the spacer from the No. 1 output shaft.

  21. REMOVE OUTPUT SHAFT BEARING SHAFT SNAP RING

    1. C112418

      Using a snap ring expander, remove the output shaft bearing shaft snap ring from the No. 1 output shaft.

  22. REMOVE INNER 2ND GEAR BEARING RACE

    1. C112419

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

  23. REMOVE 2ND DRIVEN GEAR

    1. C112420

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

  24. REMOVE NEEDLE ROLLER BEARING

    1. C112421

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

  25. REMOVE SYNCHROMESH SHIFTING KEY BALL

    1. C116562

      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. C112422

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

  27. REMOVE 1ST DRIVEN GEAR

    1. C278089N01

      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.

      09950-00020

  28. REMOVE 1ST DRIVEN GEAR SYNCHRONIZER RING SET

    1. C117926

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

  29. REMOVE NO. 1 TRANSMISSION CLUTCH HUB

    1. C117927

      Remove the No. 1 transmission clutch hub, 3 No. 1 synchromesh shifting keys, 3 balls and 3 synchromesh shifting key springs from the No. 1 transmission hub sleeve.

      Note:

      Pay attention to prevent the balls and 3 synchromesh shifting key springs from scattering.

  30. REMOVE NEEDLE ROLLER BEARING

    1. C112425

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

  31. REMOVE FRONT OUTPUT SHAFT BEARING SHAFT SNAP RING

    1. C112426

      Using a snap ring expander, remove the front output shaft bearing shaft snap ring from the No. 1 output shaft.

  32. REMOVE FRONT OUTPUT SHAFT BEARING

    1. C112427E01

      Using SST and press, press out the front output shaft bearing from the No. 1 output shaft.

      09201-31010

      09950-00020

  33. INSPECT 5TH DRIVEN GEAR THRUST CLEARANCE

    Click here

  34. INSPECT 5TH DRIVEN GEAR RADIAL CLEARANCE

    Click here

  35. INSPECT 6TH DRIVEN GEAR THRUST CLEARANCE

    Click here

  36. INSPECT 6TH DRIVEN GEAR RADIAL CLEARANCE

    Click here

  37. INSPECT REVERSE DRIVEN GEAR THRUST CLEARANCE

    Click here

  38. INSPECT REVERSE DRIVEN GEAR RADIAL CLEARANCE

    Click here

  39. REMOVE NO. 2 OUTPUT SHAFT BEARING SNAP RING

    1. C112395

      Using a snap ring expander, remove the No. 2 output shaft bearing snap ring from the No. 2 output shaft.

  40. REMOVE REAR NO. 2 OUTPUT SHAFT BEARING

    1. C112396E01

      Using SST and press, press out the rear No. 2 output shaft bearing and 6th driven gear from the No. 2 output shaft.

      09201-31010

      09950-00020

  41. REMOVE NEEDLE ROLLER BEARING

    1. C116204

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

  42. REMOVE SPACER

    1. C116203

      Remove the spacer from the No. 2 output shaft.

  43. REMOVE 6TH GEAR SYNCHRONIZER RING

    1. C116202

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

  44. REMOVE SHAFT SNAP RING

    1. C112397

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

      Note:

      Use a piece of cloth to prevent the snap ring from flying off.

  45. REMOVE 5TH DRIVEN GEAR

    1. C112398E01

      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.

      09950-00020

  46. REMOVE 5TH DRIVEN GEAR SYNCHRONIZER RING

    1. C117928

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

  47. REMOVE NO. 3 TRANSMISSION CLUTCH HUB

    1. C117929

      Remove the No. 3 transmission clutch hub, 3 No. 1 synchromesh shifting keys, 3 balls and 3 synchromesh shifting key springs from the No. 3 transmission hub sleeve.

      Note:

      Pay attention to prevent the balls and 3 synchromesh shifting key springs from scattering.

  48. REMOVE OUTPUT SHAFT COLLAR

    1. C112400

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

  49. REMOVE 5TH GEAR NEEDLE ROLLER BEARING

    1. C112401

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

  50. REMOVE 5TH GEAR BEARING SPACER

    1. C112402

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

  51. REMOVE SHAFT SNAP RING

    1. C112403

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

      Note:

      Use a piece of cloth to prevent the snap ring from flying off.

  52. REMOVE REVERSE DRIVEN GEAR

    1. C112404E01

      Using SST and 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.

      09950-00020

  53. REMOVE REVERSE DRIVEN GEAR SYNCHRONIZER RING

    1. C117930

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

  54. REMOVE NO. 4 TRANSMISSION CLUTCH HUB

    1. C117931C04

      *1

      No. 4 Transmission Clutch Hub

      *2

      Shifting Key

      *3

      Key Spring

      *4

      No. 4 Transmission Hub Sleeve

      Remove the No. 4 transmission clutch hub, shifting key and key spring from the No. 4 transmission hub sleeve.

  55. REMOVE NEEDLE ROLLER BEARING

    1. C112406

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

  56. REMOVE NO. 2 OUTPUT SHAFT FRONT BEARING

    1. C112407E01

      Using SST and press, press out the No. 2 output shaft front bearing from the No. 2 output shaft.

      09201-31010

      09950-00020