Output Shaft -- Disassembly |
| 1. INSPECT 1ST GEAR THRUST CLEARANCE |
Using a feeler gauge, measure the 1st gear thrust clearance.
- Standard clearance:
- 0.10 to 0.40 mm (0.00394 to 0.0157 in.)
- Maximum clearance:
- 0.40 mm (0.0157 in.)
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| 2. INSPECT 2ND GEAR THRUST CLEARANCE |
Using a dial indicator, measure the 2nd gear thrust clearance.
- Standard clearance:
- 0.10 to 0.55 mm (0.00394 to 0.0217 in.)
- Maximum clearance:
- 0.55 mm (0.0217 in.)
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| 3. INSPECT 1ST GEAR RADIAL CLEARANCE |
Using a dial indicator, measure the 1st gear radial clearance.
- Standard clearance:
- NSK made bearing:
- 0.015 to 0.056 mm (0.000591 to 0.00220 in.)
- JTEKT made bearing:
- 0.015 to 0.058 mm (0.000591 to 0.00228 in.)
- Maximum clearance:
- NSK made bearing:
- 0.056 mm (0.00220 in.)
- JTEKT made bearing:
- 0.058 mm (0.00228 in.)
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| 4. INSPECT 2ND GEAR RADIAL CLEARANCE |
Using a dial indicator, measure the 2nd gear radial clearance.
- Standard clearance:
- NSK made bearing:
- 0.015 to 0.056 mm (0.000591 to 0.00220 in.)
- JTEKT made bearing:
- 0.015 to 0.058 mm (0.000591 to 0.00228 in.)
- Maximum clearance:
- NSK made bearing:
- 0.056 mm (0.00220 in.)
- JTEKT made bearing:
- 0.058 mm (0.00228 in.)
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| 5. REMOVE 4TH DRIVEN GEAR |
Using SST and a press, remove the output shaft rear bearing and 4th driven gear from the output shaft.
- SST
- 09950-00020
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| 6. REMOVE OUTPUT GEAR SPACER |
Remove the output gear spacer from the output shaft.
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| 7. REMOVE 2ND GEAR |
Using SST and a press, remove the 3rd driven gear with the 2nd gear from the output shaft.
- SST
- 09950-00020
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| 8. REMOVE 2ND GEAR NEEDLE ROLLER BEARING |
Remove the 2nd gear needle roller bearing and 2nd gear bearing spacer from the output shaft.
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| 9. REMOVE NO. 2 SYNCHRONIZER RING SET (FOR 2ND GEAR) |
Remove the No. 2 synchronizer ring set from the output shaft.
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| 10. REMOVE 1ST GEAR |
Using 2 screwdrivers and a hammer, remove the No. 1 clutch hub shaft snap ring from the output shaft.
- HINT:
- Use a piece of cloth to keep the shaft snap ring from flying off.
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Using SST and a press, remove the No. 1 clutch hub assembly and 1st gear from the output shaft.
- SST
- 09950-00020
- NOTICE:
- Do not tighten SST excessively.
- Support the output shaft by hand to prevent it from dropping off.
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| 11. REMOVE NO. 1 SYNCHRONIZER RING SET (FOR 1ST GEAR) |
Remove the No. 1 synchronizer ring set from the 1st gear.
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| 12. REMOVE 1ST GEAR NEEDLE ROLLER BEARING |
Remove the 1st gear needle roller bearing from the output shaft.
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| 13. REMOVE 1ST GEAR THRUST WASHER |
Remove the 1st gear thrust washer from the output shaft.
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| 14. REMOVE 1ST GEAR THRUST WASHER PIN OR BALL |
Remove the 1st gear thrust washer pin or ball from the output shaft.
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| 15. REMOVE REVERSE GEAR |
Remove the reverse gear, 3 synchromesh shifting keys, and 3 synchromesh shifting key springs from the No. 1 transmission clutch hub.
- NOTICE:
- Use a piece of cloth to keep the shifting keys and shifting key springs from flying off.
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