Output Shaft (For Hatchback) Disassembly
INSPECT 1ST GEAR THRUST CLEARANCE
INSPECT 2ND GEAR THRUST CLEARANCE
INSPECT 1ST GEAR RADIAL CLEARANCE
INSPECT 2ND GEAR RADIAL CLEARANCE
REMOVE 4TH DRIVEN GEAR
REMOVE OUTPUT GEAR SPACER
REMOVE 2ND GEAR
REMOVE 2ND GEAR NEEDLE ROLLER BEARING
REMOVE NO. 1 SYNCHRONIZER RING (FOR 2ND GEAR)
REMOVE 1ST GEAR
REMOVE NO. 1 SYNCHRONIZER RING (FOR 1ST GEAR)
REMOVE 1ST GEAR NEEDLE ROLLER BEARING
REMOVE 1ST GEAR THRUST WASHER
REMOVE 1ST GEAR THRUST WASHER PIN OR BALL
REMOVE REVERSE GEAR
Output Shaft (For Hatchback) -- 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.)
If the clearance exceeds the maximum, replace the 1st gear thrust washer, 1st gear, or No. 1 transmission clutch hub.
| 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.)
If the clearance exceeds the maximum, replace the No. 1 transmission clutch hub, 2nd gear, or 3rd driven gear.
| 3. INSPECT 1ST GEAR RADIAL CLEARANCE |
Using a dial indicator, measure the 1st gear radial clearance between the gear and shaft.
- Standard clearance:
- JTEKT made:
- 0.015 to 0.058 mm (0.000591 to 0.00228 in.)
- NSK made:
- 0.015 to 0.056 mm (0.000591 to 0.00220 in.)
- Maximum clearance:
- JTEKT made:
- 0.058 mm (0.00228 in.)
- NSK made:
- 0.056 mm (0.00220 in.)
If the clearance exceeds the maximum, replace the 1st gear or 1st gear needle roller bearing.
| 4. INSPECT 2ND GEAR RADIAL CLEARANCE |
Using a dial indicator, measure the 2nd gear radial clearance between the gear and shaft.
- Standard clearance:
- JTEKT made:
- 0.015 to 0.058 mm (0.000591 to 0.00228 in.)
- NSK made:
- 0.015 to 0.056 mm (0.000591 to 0.00220 in.)
- Maximum clearance:
- JTEKT made:
- 0.058 mm (0.00228 in.)
- NSK made:
- 0.056 mm (0.00220 in.)
If the clearance exceeds the maximum, replace the 2nd gear or 2nd gear needle roller bearing.
| 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
| 6. REMOVE OUTPUT GEAR SPACER |
Remove the output gear spacer from the output shaft.
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 |
Remove the 2nd gear needle roller bearing and 2nd gear bearing spacer from the output shaft.
| 9. REMOVE NO. 1 SYNCHRONIZER RING (FOR 2ND GEAR) |
Remove the No. 1 synchronizer ring from the output shaft.
Using 2 screwdrivers and a hammer, remove the snap ring from the output shaft.
- HINT:
- Use a piece of cloth to keep the snap ring from flying off.
Using SST and a press, remove the No. 1 transmission clutch hub assembly and 1st gear from the output shaft.
- SST
- 09950-00020
- NOTICE:
- Do not tighten SST excessively.
- Support the input shaft by hand to prevent it from dropping off.
| 11. REMOVE NO. 1 SYNCHRONIZER RING (FOR 1ST GEAR) |
Remove the No. 1 synchronizer ring from the 1st gear.
| 12. REMOVE 1ST GEAR NEEDLE ROLLER BEARING |
Remove the 1st gear needle roller bearing from the output shaft.
| 13. REMOVE 1ST GEAR THRUST WASHER |
Remove the 1st gear thrust washer from the output shaft.
| 14. REMOVE 1ST GEAR THRUST WASHER PIN OR BALL |
Remove the 1st gear thrust washer pin or ball from the output shaft.
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 key and shifting key spring from flying off.
