OUTPUT SHAFT DISASSEMBLY

PROCEDURE

1. INSPECT 1ST GEAR THRUST CLEARANCE

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2. INSPECT 2ND GEAR THRUST CLEARANCE

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3. INSPECT 1ST GEAR RADIAL CLEARANCE

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4. INSPECT 2ND GEAR RADIAL CLEARANCE

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5. REMOVE 6TH DRIVEN GEAR

   1. 

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

      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. 

      Remove the output gear spacer from the output shaft.

7. REMOVE 4TH DRIVEN GEAR

   1. 

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

      09527-21011

      09950-60010

      09951-00290

      Note:

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

8. REMOVE OUTPUT GEAR SPACER

   1. 

      Remove the output gear spacer from the output shaft.

9. REMOVE 2ND GEAR

   1. 

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

      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. 

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

11. REMOVE INNER 2ND GEAR BEARING RACE

    1. 

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

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

    1. 

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

13. REMOVE REVERSE GEAR

    1. 

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

14. REMOVE NO. 1 SYNCHROMESH SHIFTING KEY

    1. 

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

15. REMOVE NO. 1 TRANSMISSION CLUTCH HUB

    1. 

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

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

    1. 

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

17. REMOVE 1ST GEAR

    1. 

       Remove the 1st gear from the output shaft.

18. REMOVE 1ST GEAR NEEDLE ROLLER BEARING

    1. 

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

19. REMOVE 1ST GEAR BUSH

    1. 

       Remove the 1st gear bush from the output shaft.

20. REMOVE FRONT OUTPUT SHAFT BEARING

    1. 

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

       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.