Output Shaft -- Disassembly |
| 1. INSPECT 1ST GEAR THRUST CLEARANCE |
Using a dial indicator, measure the thrust clearance.
- Standard clearance:
- 0.20 to 0.45 mm (0.00787 to 0.0177 in.)
- If the clearance is not as specified, replace the No. 1 synchronizer ring set.
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| 2. INSPECT 2ND GEAR THRUST CLEARANCE |
Using a dial indicator, measure the thrust clearance.
- Standard clearance:
- 0.10 to 0.25 mm (0.00394 to 0.00984 in.)
- If the clearance is not as specified, replace the No. 1 synchronizer ring set.
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| 3. INSPECT 3RD GEAR THRUST CLEARANCE |
Using a feeler gauge, measure the thrust clearance.
- Standard clearance:
- 0.10 to 0.25 mm (0.00394 to 0.00984 in.)
- If the clearance is not as specified, replace the No. 2 synchronizer ring set.
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| 4. INSPECT 1ST GEAR RADIAL CLEARANCE |
Using a dial indicator, measure the radial clearance.
- Standard clearance:
- 0.020 to 0.073 mm (0.000785 to 0.00287 in.)
- If the clearance is not as specified, replace the 1st gear needle roller bearing with a new one.
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| 5. INSPECT 2ND GEAR RADIAL CLEARANCE |
Using a dial indicator, measure the radial clearance.
- Standard clearance:
- 0.015 to 0.068 mm (0.000591 to 0.00267 in.)
- If the clearance is not as specified, replace the 2nd gear needle roller bearing with a new one.
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| 6. INSPECT 3RD GEAR RADIAL CLEARANCE |
Using a dial indicator, measure the radial clearance.
- Standard clearance:
- 0.015 to 0.068 mm (0.000591 to 0.00267 in.)
- If the clearance is not as specified, replace the 3rd gear needle roller bearing with a new one.
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| 7. REMOVE 1ST GEAR |
Using SST and a press, remove the 5th gear, output shaft center bearing, 1st gear thrust washer and 1st gear from the output shaft.
- SST
- 09950-00020
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| 8. REMOVE NO. 1 SYNCHRONIZER RING SET (for 1st Gear) |
Remove the synchronizer rings from the output shaft.
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| 9. REMOVE 1ST GEAR THRUST WASHER PIN |
Remove the thrust washer pin from the output shaft.
| 10. REMOVE 1ST GEAR NEEDLE ROLLER BEARING |
Remove the needle roller bearing from the output shaft.
| 11. REMOVE 1ST GEAR BEARING SPACER |
Remove the bearing spacer from the output shaft.
| 12. REMOVE BEARING SHAFT SNAP RING |
Using 2 screwdrivers and a hammer, tap off the snap ring from the output shaft.
- NOTICE:
- Use a piece of cloth to prevent the snap ring from flying off.
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| 13. REMOVE 2ND GEAR |
Using SST and a press, remove the No. 1 transmission clutch hub with the reverse gear, the No. 1 synchronizer ring set and the 2nd gear from the output shaft.
- SST
- 09950-00020
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| 14. REMOVE 2ND GEAR NEEDLE ROLLER BEARING |
Remove the needle roller bearing from the output shaft.
| 15. REMOVE REVERSE GEAR |
Remove the reverse gear, 3 No. 1 synchromesh shifting keys and 3 synchromesh shifting key springs.
- NOTICE:
- Use a piece of cloth to prevent the shifting keys and shifting key springs from popping out.
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| 16. REMOVE CLUTCH HUB SET SHAFT SNAP RING |
Using a snap ring expander, remove the snap ring from the output shaft.
- NOTICE:
- Do not damage the sliding surface of the bearing.
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| 17. REMOVE 3RD GEAR |
Using SST and a press, remove the No. 2 transmission clutch hub with the No. 2 transmission hub sleeve, the No. 2 synchronizer ring and the 3rd gear from the output shaft.
- SST
- 09950-00020
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| 18. REMOVE 3RD GEAR NEEDLE ROLLER BEARING |
Remove the needle roller bearing from the output shaft.
| 19. REMOVE NO. 2 TRANSMISSION HUB SLEEVE |
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.
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