Output Shaft Disassembly

1. MEASURE 1ST AND 2ND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.

Standard clearance:
1st gear: 0.10 - 0.35 mm (0.0039 - 0.0138 in.)
2nd gear: 0.10 - 0.45 mm (0.0039 - 0.0177 in.)

Maximum clearance:
1st gear: 0.40 mm (0.0157 in.)
2nd gear: 0.50 mm (0.0197 in.)




2. CHECK 1ST AND 2ND GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between the gear and shaft.

Standard clearance:
1st gear: 0.009 - 0.051 mm (0.0004 - 0.0020 in.)
2nd gear: 0.009 - 0.053 mm (0.0004 - 0.0021 in.)

Maximum clearance:
1st and 2nd gear: 0.070 mm (0.0028 in.)




If the clearance exceeds the limit, replace the gear, needle roller bearing or shaft.
3. REMOVE OUTPUT SHAFT REAR BEARING, 4TH DRIVEN GEAR AND SPACER
a. Using a press, remove the bearing and 4th driven gear.
b. Remove the spacer.




4. REMOVE 3RD DRIVEN GEAR AND 2ND GEAR
Using a press, remove the 3rd driven gear and 2nd gear.
5. REMOVE NEEDLE ROLLER BEARING, SPACER AND SYNCHRONIZER RINGS
6. REMOVE SNAP RING
Using a snap ring expander, remove the snap ring.




7. REMOVE NO.1 HUB SLEEVE ASSEMBLY AND 1ST GEAR
Using a press, remove the No.1 hub sleeve and 1st gear.
8. REMOVE SYNCHRONIZER RING AND NEEDLE ROLLER BEARING




9. REMOVE OUTPUT SHAFT FRONT BEARING
Using SST, remove the output shaft front bearing.
SST 09950-00020, 09950-00030