OUTPUT SHAFT DISASSEMBLY

PROCEDURE


  1. INSPECT THRUST CLEARANCE


    1. A004KR4E01
      Text in Illustration
      *a Reverse gear thrust clearance
      *b 2nd gear thrust clearance
      *c 1st gear thrust clearance

      Using a feeler gauge, measure the thrust clearance of the 1st gear, 2nd gear and reverse gear.

      Standard Clearance
      Gear Standard clearance mm (in.) Maximum clearance mm (in.)
      1st gear 0.15 to 0.40 (0.00590 to 0.0157) 0.40 (0.0157)
      2nd gear 0.10 to 0.45 (0.000394 to 0.0177) 0.45 (0.0177)
      Reverse gear 0.10 to 0.45 (0.000394 to 0.0177) 0.45 (0.0177)

      Tech Tips

      If the clearance exceeds the maximum, replace the corresponding gear, transmission clutch hub, needle roller bearing and output shaft with a new ones.

  2. INSPECT RADIAL CLEARANCE


    1. A004K90E01
      Text in Illustration
      *a Reverse gear radial clearance
      *b 2nd gear radial clearance
      *c 1st gear radial clearance

      Using a dial indicator, measure the radial clearance of the 1st gear, 2nd gear and reverse gear.

      Standard Clearance
      Gear Standard clearance mm (in.) Maximum clearance mm (in.)
      1st gear 0.015 to 0.066 (0.000590 to 0.00260) 0.066 (0.00260)
      2nd gear 0.015 to 0.066 (0.000590 to 0.00260) 0.066 (0.00260)
      Reverse gear 0.015 to 0.066 (0.000590 to 0.00260) 0.066 (0.00260)

      Tech Tips

      If the clearance exceeds the maximum, replace the corresponding gear, needle roller bearing and output shaft with a new ones.

  3. REMOVE REVERSE GEAR


    1. A004KNR

      Using a snap ring expander, remove the shaft snap ring.

    2. A004HM8E02

      Using SST and a press, remove the No. 3 transmission clutch hub, No. 3 transmission hub sleeve, reverse gear, No. 3 synchronizer ring and reverse gear bearing from the output shaft.

      SST
      09950-00020
      09950-60010   ( 09951-00230 )
      09950-70010   ( 09951-07100 )

  4. REMOVE NO. 3 TRANSMISSION HUB SLEEVE


    1. A004JH9

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

      Note


      • Use a cloth to prevent the No. 1 synchromesh shifting keys, No. 1 synchromesh shifting key springs and balls from popping out.

      • Do not deform the No. 1 synchromesh shifting key spring.

      Tech Tips

      During this operation, keep intact the No. 3 transmission clutch hub and No. 1 synchromesh shifting key.

  5. REMOVE 6TH GEAR


    1. A004I2M

      Using 2 screwdrivers and a hammer, remove the shaft snap ring.

    2. A004KK1E02

      Using SST and a press, remove the 6th gear.

      SST
      09950-00020

  6. REMOVE 1ST GEAR


    1. A004K6DE02

      Using SST and a press, remove the rear output shaft bearing, 1st gear and 1st gear bearing inner race.

      SST
      09950-00020
    2. A004HV7

      Remove the 1st gear needle roller bearing, 1st shift restrict ball and No. 1 synchronizer ring set.

  7. REMOVE 2ND GEAR


    1. A004HCEE02

      Using SST and a press, remove the 2nd gear, No. 1 transmission clutch hub and 2nd gear needle roller bearing from the output shaft.

      SST
      09950-00020

  8. REMOVE NO. 1 SYNCHRONIZER RING SET


    1. Remove the No. 1 synchronizer ring set.

  9. REMOVE NO. 1 TRANSMISSION HUB SLEEVE


    1. A004KLF

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

      Note


      • Use a cloth to prevent the No. 1 synchromesh shifting keys, No. 1 synchromesh shifting key springs and balls from popping out.

      • Do not deform the No. 1 synchromesh shifting key spring.

      Tech Tips

      During this operation, keep the No. 1 transmission clutch hub and No. 1 synchromesh shifting key intact.