Disassembly of Output Shaft Assembly

1. MEASURE FIRST AND SECOND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.

Standard clearance:
1st gear 0.10 - 0.29 mm (0.0039 - 0.0114 in.)
2nd gear 0.20 - 0.44 mm (0.0079 - 0.0173 in.)

Maximum clearance:
1st gear 0.35 mm (0.0138 in.)
2nd gear 0.50 mm (0.0197 in.)




2. CHECK OIL CLEARANCE OF FIRST AND SECOND GEAR
Using dial indicator, measure the oil clearance between the gear and shaft.

Standard clearance: 0.009 - 0.053 mm (0.0004 - 0.0021 in.)
Maximum clearance: 0.070 mm (0.0028 in.)

If the clearance exceeds the limit, replace the gear, needle roller bearing or shaft.




3. REMOVE REAR BALL BEARING, FOURTH DRIVEN GEAR AND OUTPUT GEAR SPACER FROM OUTPUT SHAFT
a. Using SST and a press, remove the rear ball bearing and 4th driven gear.
SST 09950-00020
b. Remove the output gear spacer and ball.




4. REMOVE THIRD DRIVEN GEAR, SECOND GEAR, NEEDLE ROLLER BEARING AND SYNCHRONIZER RING
a. Shift No.1 hub sleeve into the 1st gear.




b. Using SST and a press, remove the 3rd driven gear and 2nd gear.
SST 09950-00020
c. Remove the needle roller bearing and synchronizer ring.




5. REMOVE NO.1 HUB SLEEVE ASSEMBLY, FIRST GEAR, SYNCHRONIZER RING, NEEDLE ROLLER BEARING,THRUST WASHER AND LOCKING BALL
a. Using a press, remove No.1 hub sleeve, 1St gear and synchronizer ring.
b. Remove the needle roller bearing and locking ball.




c. Using a screwdriver and hammer, drive out the thrust washer.