Disassembly

C59 MANUAL TRANSAXLE: OUTPUT SHAFT: DISASSEMBLY

DISASSEMBLY

1. INSPECT 1ST GEAR THRUST CLEARANCE (Output Shaft)

2. INSPECT 2ND GEAR THRUST CLEARANCE (Output Shaft)

3. INSPECT 1ST GEAR RADIAL CLEARANCE (Output Shaft)

4. INSPECT 2ND GEAR RADIAL CLEARANCE (Output Shaft)

5. REMOVE 4TH DRIVEN GEAR





(a) Using SST and a press, remove the output shaft rear bearing with 4th driven gear from the output shaft.
SST: 09950-00020
6. REMOVE OUTPUT GEAR SPACER





(a) Remove the output gear spacer from the output shaft.
7. REMOVE 2ND GEAR





(a) Using SST and a press, remove the 3rd driven gear with 2nd gear from the output shaft.
SST: 09950-00020
8. REMOVE 2ND GEAR NEEDLE ROLLER BEARING





(a) Remove the 2nd gear needle roller bearing and 2nd gear bearing spacer from the output shaft.
9. REMOVE SYNCHRONIZER RING SET NO. 2





(a) Remove the synchronizer ring set No. 2 from the output shaft.
10. REMOVE 1ST GEAR





(a) Using 2 screwdrivers and a hemmer, tap out the snap ring.

HINT: Use a shop rag or piece of cloth to keep the snap ring from flying.





(b) Using SST and a press, remove the transmission clutch hub No. 1 with 1st gear from the output shaft.
SST: 09950-00020

- Do not tighten SST excessively.
- Support the input shaft by hand so that it will not be dropped off.

11. REMOVE SYNCHRONIZER RING NO. 1





(a) Remove the synchronizer ring No. 1 from the 1st gear.
12. REMOVE 1ST GEAR NEEDLE ROLLER BEARING





(a) Remove the 1st gear needle roller bearing from the output shaft.
13. REMOVE 1ST GEAR THRUST WASHER





(a) Remove the 1st gear thrust washer from the output shaft.
14. REMOVE 1ST GEAR THRUST WASHER PIN OR BALL





(a) Remove the 1st gear thrust washer pin or ball from the output shaft.
15. REMOVE REVERSE GEAR





(a) Remove the 3 synchromesh shifting keys, 3 synchromesh shifting key springs and reverse gear.

HINT: Use a shop rag or piece of cloth to keep the shifting key and shifting key spring from flying.

16. REMOVE OUTPUT SHAFT FRONT BEARING





(a) Using 2 screwdrivers, remove the snap ring.

HINT: Use a shop rag or piece of cloth to keep the snap ring from flying.

(b) Using SST and a press, remove the output shaft front bearing from the output shaft.
SST: 09950-00020
17. INSPECT OUTPUT SHAFT (Output Shaft)

18. INSPECT 2ND GEAR (Output Shaft)

19. INSPECT 1ST GEAR (Output Shaft)

20. INSPECT 1ST GEAR THRUST WASHER (Output Shaft)

21. INSPECT SYNCHRONIZER RING SET NO. 2 (Output Shaft)

22. INSPECT SYNCHRONIZER RING NO. 1 (Output Shaft)

23. INSPECT REVERSE GEAR (Output Shaft)

24. INSPECT TRANSMISSION CLUTCH HUB NO. 1 (Output Shaft)