Output Shaft Removal

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.20 to 0.45 mm (0.0079 to 0.0177 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:

0.020 to 0.073 mm (0.0008 to 0.0029 in.)

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.015 to 0.068 mm (0.0006 to 0.0027 in.)

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.015 to 0.068 mm (0.0006 to 0.0027 in.)

Using SST and a press, press out the 5th gear, the output shaft center bearing, the 1st gear thrust washer and the 1st gear from the output shaft.

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Remove the synchronizer ring from the output shaft.

Remove the thrust washer pin from the output shaft.

Remove the needle roller bearing from the output shaft.

Remove the bearing spacer from the output shaft.

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

NOTICE:

Use a cloth to prevent the snap ring from flying off.

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

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Remove the needle roller bearing from the output shaft.

Remove the reverse gear, 3 No. 1 synchromesh shifting keys, and 3 synchromesh shifting key springs.

NOTICE:

Use a cloth to prevent the shifting key and the shifting key springs from popping out.

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

NOTICE:

Do not damage the sliding surface of the bearing.

Using SST and a press, press out the No. 2 transmission clutch hub (with the No. 2 transmission hub sleeve, No. 2 synchronizer ring and 3rd gear) from the output shaft.

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Remove the needle roller bearing from the output shaft.

Remove the No. 2 hub sleeve, 3 No. 2 synchromesh shifting key springs, and 3 No. 2 synchromesh shifting keys from the No. 2 clutch hub.

Using a dial indicator, measure the output shaft runout.

Maximum runout:

0.03 mm (0.0012 in.)

Using a micrometer, measure the diameter at A, B and C on the output shaft.

Standard diameter:

Mark	Standard condition
A	38.979 to 38.995 mm (1.5334 to 1.5352 in.)
B	46.984 to 47.000 mm (1.8498 to 1.8504 in.)
C	37.984 to 38.000 mm (1.4954 to 1.4961 in.)

Using a micrometer, measure the thickness of the output shaft flange as shown in the illustration.

Standard thickness:

4.8 to 5.2 mm (0.1890 to 0.2047 in.)

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.)

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

Standard inside diameter:

53.015 to 53.040 mm (2.0872 to 2.0881 in.)

Maximum inside diameter:

53.040 mm (2.0881 in.)

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

Standard inside diameter:

46.015 to 46.040 mm (1.812 to 1.8126 in.)

Maximum inside diameter:

46.040 mm (1.8126 in.)

Using a micrometer, measure the thickness of the thrust washer.

Standard thickness:

5.95 to 6.05 mm (0.2346 to 0.2382 in.)

Minimum thickness:

5.95 mm (0.2346 in.)

Apply gear oil to the cone of the 1st gear, and check that it does not turn in both directions while pushing the No. 1 synchronizer ring set.
If it turns, replace the synchronizer ring.

Measure the clearance between the No. 1 synchronizer ring and 1st gear while pushing the No. 1 synchronizer ring to the cone of the 1st gear.

Standard clearance:

0.65 to 1.75 mm (0.0256 to 0.0689 in.)

Apply gear oil to the cone of the 2nd gear, and check that it does not turn in both directions while pushing the No. 1 synchronizer ring set.
If it turns, replace the No. 1 synchronizer ring set.

Push the No. 1 synchronizer ring set to the cone of the 2nd gear. Measure the clearance between the No. 1 synchronizer ring set and 2nd gear.

Standard clearance:

0.65 to 1.75 mm (0.0256 to 0.0689 in.)

Apply gear oil to the cone of the 3rd gear, and check that it does not turn in both directions while pushing the No. 2 synchronizer ring.
If it turns, replace the No. 2 synchronizer ring.

Push the No. 2 synchronizer ring to the cone of the 3rd gear. Measure the clearance between the No. 2 synchronizer ring and 3rd gear.

Standard clearance:

0.75 to 1.65 mm (0.0295 to 0.0650 in.)

Using a vernier caliper, measure the groove of the reverse gear and the thickness of the claw of the No. 1 shift fork. Then check the clearance between the groove and claw.

Standard clearance:

0.15 to 0.41 mm (0.0060 to 0.0161 in.)

Check the sliding condition between the No. 1 clutch hub and the reverse gear.

Check the tip of the spline gear sleeve of the reverse gear for wear.
If there are any defects, replace the No. 1 clutch hub.

Using a vernier caliper, measure the No. 2 hub sleeve groove and the thickness of the claw of the No. 2 shift fork.

Standard clearance:

0.15 to 0.35 mm (0.0059 to 0.0138 in.)

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

Check the tip of the spline gear of the No. 1 clutch hub for wear.

Check the tip of the spline gear sleeve of the reverse gear for wear.
If there are any defects, replace the No. 1 clutch hub or reverse gear.