Output Shaft Disassembly

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.10 to 0.30 mm (0.00394 to 0.0118 in.)

1. If the result is not as specified, replace the 5th gear.
   

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.00394 to 0.00984 in.)

1. If the result is not as specified, replace the No. 1 synchronizer ring set.
   

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.00394 to 0.00984 in.)

1. If the result is not as specified, replace the No. 1 synchronizer ring set.
   

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.00394 to 0.00984 in.)

1. If the result is not as specified, replace the No. 2 synchronizer ring set.
   

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.009 to 0.056 mm (0.000355 to 0.00220 in.)

1. If the result is not as specified, replace the 1st gear needle roller bearing.
   

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.008 to 0.034 mm (0.000315 to 0.00133 in.)

1. If the result 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 (0.000315 to 0.00133 in.)

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

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

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

SST

09527-10011

Remove the No. 1 synchronizer ring from the No. 1 clutch hub.

Using a magnet hand, remove the lock ball.

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

SST

09950-00020

Remove the No. 2 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, remove the No. 2 transmission clutch hub and 3rd gear.

Remove the No. 1 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.