OUTPUT SHAFT DISASSEMBLY

CAUTION / NOTICE / HINT

Note:

When replacing any tapered roller bearing, replace both the tapered roller bearing and tapered roller bearing outer race with new ones.

PROCEDURE

  1. REMOVE REAR OUTPUT SHAFT BEARING

    1. G021356N01

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

      09950-60010

      09951-00220

      09950-70010

      09951-07100

      Note:

      Do not damage or deform the cage of the rear output shaft bearing (when reusing the rear output shaft bearing).

  2. INSPECT 1ST GEAR THRUST CLEARANCE

    Click here

  3. INSPECT 2ND GEAR THRUST CLEARANCE

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  4. INSPECT 1ST GEAR RADIAL CLEARANCE

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  5. INSPECT 2ND GEAR RADIAL CLEARANCE

    Click here

  6. REMOVE COUNTER 5TH GEAR SHAFT SNAP RING

    1. G021399

      Using 2 screwdrivers and a hammer, remove the counter 5th gear shaft snap ring from the output shaft.

      Tip:

      Use a piece of cloth to keep the counter 5th gear shaft snap ring from flying off.

  7. REMOVE 4TH DRIVEN GEAR

    1. G021391

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

  8. REMOVE OUTPUT SHAFT SPACER

    1. G021357

      Remove the output shaft spacer from the output shaft.

  9. REMOVE 2ND GEAR

    1. G021358N01

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

      09950-00020

  10. REMOVE 2ND GEAR NEEDLE ROLLER BEARING

    1. G021384

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

  11. REMOVE 2ND GEAR BEARING SPACER

    1. G021383

      Remove the 2nd gear bearing spacer from the output shaft.

  12. REMOVE 2ND GEAR SYNCHRONIZER RING

    1. G021385

      Remove the 2nd gear synchronizer ring from the reverse gear.

  13. REMOVE NO. 1 CLUTCH HUB SHAFT SNAP RING

    1. C118338

      Using 2 screwdrivers, remove the No. 1 clutch hub shaft snap ring from the output shaft.

      Note:

      Be careful not to damage the journal surface of the output shaft.

      Tip:

      Use a piece of cloth to keep the No. 1 clutch hub shaft snap ring from flying off.

  14. REMOVE 1ST GEAR

    1. G021360

      Using a press, remove the No. 1 transmission clutch hub, 1st gear synchronizer ring and 1st gear from the output shaft.

  15. REMOVE 1ST GEAR NEEDLE ROLLER BEARING

    1. C303224

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

  16. REMOVE FRONT OUTPUT SHAFT BEARING

    1. C303214N01

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

      09950-00020

      09950-60010

      09951-00220

      09950-70010

      09951-07100

      Note:

      Do not damage or deform the cage of the front output shaft bearing (when reusing the front output shaft bearing).

  17. REMOVE NO. 1 TRANSMISSION CLUTCH HUB

    1. G021363C01

      *1

      No. 1 Shifting Key Spring

      *2

      Reverse Gear

      *3

      No. 1 Shifting Key

      *4

      No. 1 Transmission Clutch Hub

      Remove the 2 No. 1 shifting key springs, 3 No. 1 shifting keys and reverse gear from the No. 1 transmission clutch hub.