Output Shaft Removal

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.0039 to 0.0098 in.)

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.0039 to 0.0098 in.)

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.0039 to 0.0098 in.)

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.009 to 0.056 mm (0.0004 to 0.0022 in.)

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.008 to 0.034 mm (0.0003 to 0.0013 in.)

1. If the clearance is not as specified, replace the 2nd gear needle roller bearing.
   

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.008 to 0.034 mm (0.0003 to 0.0013 in.)

1. If the clearance is not as specified, replace the 3rd gear needle roller bearing.
   

Using 2 screwdrivers and a hammer, tap out the snap ring from the output shaft.

Using SST and a press, press out the 5th gear, center bearing, 1st gear, 1st gear needle roller bearing and 1st gear bearing inner race from the output shaft.

SST

09527-10011

Remove the No. 1 synchronizer ring (for the 1st gear) from the No. 1 clutch hub.

Using a magnetic finger, remove the lock ball.

Using SST and a press, press out the No. 1 transmission clutch hub, reverse gear, No. 1 synchronizer ring and 2nd gear.

SST

09950-00020

Remove the No. 1 synchronizer ring from the 2nd gear.

Remove the needle roller bearing from the output shaft.

Remove the 2 synchromesh shifting key springs.

Remove the reverse gear and 3 synchromesh shifting keys from the transmission clutch hub.

Using a snap ring expander, remove the snap ring from the output shaft.

Using a press, press out the No. 2 transmission clutch hub and 3rd gear.

Remove the synchronizer ring from the 3rd gear.

Remove the needle roller bearing from the output shaft.

Remove the 2 synchromesh shifting key springs.

Remove the transmission hub sleeve and 3 synchromesh shifting keys from the transmission clutch hub.

Using a micrometer, measure the outside diameter of the output shaft journal surface.

Standard outside diameter:

Position	Specified Condition
Part A	34.984 to 35.000 mm (1.3773 to 1.3780 in.)
Part B	37.984 to 38.000 mm (1.4945 to 1.4960 in.)
Part C	30.384 to 30.400 mm (1.1962 to 1.1968 in.)

1. If the outside diameter is not as specified, replace the output shaft.
   

Using a micrometer, measure the flange thickness.

Standard thickness:

4.80 to 5.20 mm (0.1890 to 0.2047 in.)

Minimum thickness:

4.80 mm (0.1890 in.)

1. If the thickness is less than the minimum, replace the output shaft.
   

Using a micrometer, measure the inner race thickness.

Standard thickness:

4.00 to 4.20 mm (0.1575 to 0.1654 in.)

Minimum thickness:

4.00 mm (0.1575 in.)

1. If the thickness is less than the minimum, replace the 1st gear bearing inner race.
   

Using a micrometer, measure the outside diameter of the inner race.

Standard outside diameter:

38.985 to 39.000 mm (1.5348 to 1.5354 in.)

Minimum outside diameter:

38.985 mm (1.5348 in.)

1. If the outside diameter is less than the minimum, replace the 1st gear bearing inner race.
   

Coat the 1st gear cone with gear oil. Check the braking effect of the No. 1 synchronizer ring. Fit the ring to the shaft cone. Apply pressure to the ring and attempt to turn it in both directions. Check that the ring locks.

1. If the braking effect is insufficient, apply a small amount of fine lapping compound between the No. 1 synchronizer ring and the 1st gear cone. Lightly rub the No. 1 synchronizer ring and the 1st gear cone together.
   

NOTICE:

Ensure the fine lapping compound is completely washed off after rubbing.

Check the braking effect of the No. 1 synchronizer ring again.

Using a feeler gauge, measure the clearance between the No. 1 synchronizer ring back and 1st gear spline end.

Standard clearance:

1.00 to 2.00 mm (0.0394 to 0.0787 in.)

1. If the clearance is not as specified, replace the No. 1 synchronizer ring and apply a small amount of fine lapping compound on the 1st gear cone.
   

NOTICE:

Ensure the fine lapping compound is completely washed off after rubbing.

Coat the 2nd gear cone with gear oil. Check the braking effect of the No. 1 synchronizer ring. Fit the ring to the shaft cone. Apply pressure to the ring and attempt to turn it in both directions. Check that the ring locks.

1. If the braking effect is insufficient, apply a small amount of fine lapping compound between the No. 1 synchronizer ring and the 2nd gear cone. Lightly rub the No. 1 synchronizer ring and the 2nd gear cone together.
   

NOTICE:

Ensure the fine lapping compound is completely washed off after rubbing.

Check the braking effect of the No. 1 synchronizer ring again.

Using a feeler gauge, measure the clearance between the No. 1 synchronizer ring back and 2nd gear spline end.

Standard clearance:

1.00 to 2.00 mm (0.0394 to 0.0787 in.)

1. If the clearance is not as specified, replace the No. 1 synchronizer ring, and apply a small amount of fine lapping compound on the 2nd gear cone.
   

NOTICE:

Ensure the fine lapping compound is completely washed off after rubbing.

Coat the 3rd gear cone with gear oil. Check the braking effect of the No. 2 synchronizer ring. Fit the ring to the shaft cone. Apply pressure to the ring and attempt to turn it in both directions. Check that the ring locks.

1. If the braking effect is insufficient, apply a small amount of fine lapping compound between the No. 2 synchronizer ring and the 3rd gear cone. Lightly rub the No. 2 synchronizer ring and the 3rd gear cone together.
   

NOTICE:

Ensure the fine lapping compound is completely washed off after rubbing.

Check the braking effect of the No. 2 synchronizer ring again.

Using a feeler gauge, measure the clearance between the No. 2 synchronizer ring back and 3rd gear spline end.

Standard clearance:

1.0 to 2.0 mm (0.0394 to 0.0787 in.)

1. If the clearance is not as specified, replace the No. 2 synchronizer ring and apply a small amount of fine lapping compound on the 3rd gear cone.
   

NOTICE:

Ensure the fine lapping compound is completely washed off after rubbing.

Using a vernier caliper, measure the clearance between the reverse gear and No. 1 gear shift fork.

Standard clearance:

0.15 to 0.35 mm (0.0059 to 0.0138 in.)

Minimum clearance:

0.35 mm (0.0138 in.)

1. If the clearance is less than the minimum, replace the No. 1 gear shift fork and reverse gear.
   

Check that the No. 1 transmission clutch hub and reverse gear slide smoothly.

Check that the spline gear's edges of the reverse gear are not worn down.

Using a vernier caliper, measure the No. 2 hub sleeve and No. 2 gear shift fork as shown in the illustration.

Standard clearance:

0.15 to 0.35 mm (0.0059 to 0.0138 in.)

1. If the clearance is not as specified, replace the transmission hub sleeve and the No. 2 gear shift fork.
   

Check the sliding condition between the No. 2 hub sleeve and No. 2 clutch hub.

Check that the spline gear's edges of the No. 2 transmission hub sleeve are not worn down.

Using a cylinder gauge, measure the inside diameter of the 1st gear.

Standard inside diameter:

44.015 to 44.040 mm (1.7329 to 1.7339 in.)

Maximum inside diameter:

44.040 mm (1.7339 in.)

1. If the inside diameter is greater than the maximum, replace the 1st gear.
   

Using a cylinder gauge, measure the inside diameter of the 2nd gear.

Standard inside diameter:

44.015 to 44.040 mm (1.7329 to 1.7339 in.)

Maximum inside diameter:

44.040 mm (1.7339 in.)

1. If the inside diameter is greater than the maximum, replace the 2nd gear.
   

Using a cylinder gauge, measure the inside diameter of the 3rd gear.

Standard inside diameter:

44.015 to 44.040 mm (1.7329 to 1.7339 in.)

Maximum inside diameter:

44.040 mm (1.7339 in.)

1. If the inside diameter is greater than the maximum, replace the 3rd gear.