Output Shaft
OUTPUT SHAFTCOMPONENTS:
DISASSEMBLY
1. REMOVE 4TH DRIVEN GEAR
(a) Using SST and a press, remove the output shaft rear bearing (inner race) and 4th driven gear.
SST 09950-00020
2. REMOVE OUTPUT GEAR SPACER
(a) Remove the output gear spacer from the output shaft.
3. REMOVE 2ND GEAR
(a) Using SST and a press, remove the 3rd driven gear and 2nd gear from the output shaft.
SST 09950-00020
4. REMOVE NO. 2 SYNCHRONIZER RING SET
(a) Remove the No. 2 synchronizer ring set from the No. 1 transmission clutch hub.
5. REMOVE 2ND GEAR NEEDLE ROLLER BEARING
(a) Remove the 2nd gear needle roller bearing from the output shaft.
6. REMOVE 2ND GEAR BEARING SPACER
(a) Remove the 2nd gear bearing spacer from the output shaft.
7. REMOVE 2ND GEAR BUSHING
(a) Remove the 2nd gear bushing from the output shaft.
8. REMOVE 2ND GEAR BUSHING BALL
(a) Using a magnetic finger, remove the 2nd gear bush ball from the output shaft.
9. REMOVE 1ST GEAR
(a) Using SST and a press, remove the No. 1 transmission clutch hub and 1st gear from the output shaft.
SST 09950-00020
10. REMOVE NO. 1 SYNCHRONIZER RING SET
(a) Remove the No. 1 synchronizer ring set from the 1st gear.
11. REMOVE 1ST GEAR NEEDLE ROLLER BEARING
(a) Remove the 1st gear needle roller bearing from the output shaft.
12. REMOVE OUTPUT SHAFT FRONT BEARING
(a) Using SST and a press, remove the output shaft front bearing (inner race) from the output shaft.
SST 09950-00020, 09950-60010 (09951-00320), 09950-70010 (09951-07150)
NOTICE: Do not overtighten the SST.
13. REMOVE REVERSE GEAR
(a) Remove the No. 1 transmission clutch hub, 3 No. 1 synchromesh shifting keys, and 3 No. 1 synchromesh shifting key springs from the reverse gear.
INSPECTION
1. INSPECT 1ST GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the 1st gear thrust clearance.
Standard clearance: 0.25 to 0.40 mm (0.0098 to 0.0157 inch)
If clearance is out of specification, replace the 1st gear, thrust washer, 1st gear, or No. 1 transmission clutch hub.
2. INSPECT 2ND GEAR THRUST CLEARANCE
(a) Using a dial indicator, measure the 2nd gear thrust clearance.
Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 inch)
If clearance is out of specification, replace the No. 1 transmission clutch hub, 2nd gear, or 3rd driven gear.
3. INSPECT 1ST GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 1st gear radial clearance.
Standard clearance mm (inch):
If clearance is out of specification, replace the 1st gear and 1st gear needle roller bearing.
4. INSPECT 2ND GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the 2nd gear radial clearance.
Standard clearance mm (inch):
If clearance is out of specification, replace the 2nd gear and 2nd gear needle roller bearing.
5. INSPECT OUTPUT SHAFT
(a) Using a V-block and a dial indicator, inspect the shaft for runout.
Maximum runout: 0.03 mm (0.0012 inch)
If runout exceeds the maximum, replace the input shaft.
(b) Using a micrometer, measure the outside diameter of the output shaft journal surface.
Outside diameter mm (inch):
If the outside diameter is less than the minimum, replace the input shaft.
6. INSPECT 2ND GEAR
(a) Using a cylinder gauge, measure the inside diameter of the 2nd gear.
Inside diameter: mm (inch):
If the inside diameter exceeds the maximum, replace the 2nd gear.
7. INSPECT 1ST GEAR
(a) Using a cylinder gauge, measure the inside diameter of the 1st gear.
Inside diameter mm (inch):
If the inside diameter exceeds the maximum, replace the 1st gear.
8. INSPECT NO. 2 SYNCHRONIZER RING SET
(a) Coat the 2nd gear cone with gear oil. Turn the No. 2 synchronizer ring set in one direction while pushing it against the No. 2 synchronizer ring. Check that the ring locks.
If the No. 2 synchronizer ring set does not lock, replace the ring or 2nd gear.
(b) Check the clearance between the No. 2 synchronizer ring and 2nd gear while pushing the 2nd gear against the No. 2 synchronizer ring.
Standard clearance: 0.70 to 1.45 mm (0.0276 to 0.0571 inch)
If clearance is out of specification, replace the No. 2 synchronizer ring set with a new one.
9. INSPECT NO. 1 SYNCHRONIZER RING SET
(a) Coat the 1st gear cone with gear oil. Turn the No. 1 synchronizer ring set in one direction while pushing it against the 1st gear cone. Check that the ring locks.
If the No. 1 synchronizer ring set does not lock, replace the No. 1 synchronizer ring set with a new one.
(b) Check the clearance between the No. 1 synchronizer ring set and 1st gear while pushing the 1st gear against the cone of the No. 1 synchronizer ring set.
Standard clearance: 0.70 to 1.45 mm (0.0276 to 0.0571 inch)
If clearance is out of specification, replace the No. 1 synchronizer ring set with a new one.
10. INSPECT REVERSE GEAR
(a) Using vernier calipers, measure the width of the reverse gear groove and thickness of the claw part on the No. 1 gear shift fork, and calculate the clearance.
Standard clearance: 0.15 to 0.35 mm (0.0059 to 0.0138 inch) {A - B}
If clearance is out of specification, replace the reverse gear and No. 1 gear shift fork with new ones.
11. INSPECT NO. 1 TRANSMISSION CLUTCH HUB
(a) Check the sliding condition between the No. 1 transmission clutch hub and the reverse gear.
(b) Check the tip of the spline gear on the sleeve of the reverse gear for wear.
If any defects are found, replace the transmission hub sleeve or the transmission clutch hub.
REASSEMBLY
1. INSTALL REVERSE GEAR
(a) Coat the reverse gear with gear oil.
(b) Install the 3 No. 1 synchromesh shifting key springs and No. 1 transmission clutch hub to the reverse gear.
NOTICE: Assemble the reverse gear and the No. 1 transmission clutch hub in the correct direction.
(c) Using a screwdriver, install the 3 No. 1 synchromesh shifting keys to the reverse gear.
2. INSTALL OUTPUT SHAFT FRONT BEARING
(a) Using SST and a press, install the output shaft front bearing (inner race) to the output shaft.
SST 09950-60010 (09951-00430), 09950-70010 (09951-07150)
3. INSTALL NO. 1 SYNCHRONIZER RING SET
(a) Coat the No. 1 synchronizer ring set with gear oil and install it to the 1st gear.
NOTICE: Align the No. 1 synchronizer ring set with the hole of the 1st gear.
4. INSTALL 1ST GEAR NEEDLE ROLLER BEARING
(a) Coat the 1st gear needle roller bearing with gear oil and install it to the output shaft.
5. INSTALL 1ST GEAR
(a) Coat the 1st gear with gear oil and install it to the output shaft.
6. INSTALL NO. 1 TRANSMISSION CLUTCH HUB
(a) Using SST and a press, install the No. 1 transmission clutch hub to the output shaft.
SST 09316-60011 (09316-00031), 09950-60010 (09951-00320), 09950-70010 (09951-07100)
NOTICE:
^ Align the No. 1 synchronizer ring with the No. 1 synchromesh shifting key.
^ Make sure that the 1st gear rotates.
7. INSTALL 2ND GEAR BUSHING BALL
(a) Coat the gear bushing with MP grease, and install it to the output shaft.
8. INSTALL 2ND GEAR BUSHING
(a) Coat the 2nd gear bushing with gear oil and install it to the output shaft.
9. INSTALL 2ND GEAR BEARING SPACER
(a) Coat the 2nd gear bearing spacer with gear oil and install it to the output shaft.
10. INSTALL 2ND GEAR NEEDLE ROLLER BEARING
(a) Coat the 2nd gear needle roller bearing with gear oil and install it to the output shaft.
11. INSTALL NO. 2 SYNCHRONIZER RING SET
(a) Coat the No. 2 synchronizer ring set with gear oil and install it to the No. 1 transmission clutch hub.
NOTICE: Align the key groove on the No. 2 synchronizer ring set with the No. 1 synchromesh shifting key.
12. INSTALL 2ND GEAR
(a) Coat the 2nd gear with gear oil and install it to the output shaft.
13. INSTALL 3RD DRIVEN GEAR
(a) Using SST and a press, install the 3rd driven gear to the output shaft.
SST 09608-00071, 09950-60010 (09951-00320), 09950-70010 (09951-07100)
14. INSTALL OUTPUT GEAR SPACER
(a) Install the output gear spacer to the output shaft.
15. INSTALL 4TH DRIVEN GEAR
(a) Using SST and a press, install the 4th driven gear to the output shaft.
SST 09608-00071, 09950-60010 (09951-00320), 09950-70010 (09951-07100)
16. INSTALL OUTPUT SHAFT FRONT BEARING
(a) Using SST and a press, install the output shaft front bearing (inner race) to the output shaft.
SST 09506-30012, 09950-60010 (09951-00320), 09950-70010 (09951-07100)