Output Shaft (For Sedan) 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 SYNCHRONIZER RING NO.1 (FOR 2ND GEAR)
REMOVE 1ST GEAR
REMOVE SYNCHRONIZER RING GEAR NO.1 (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 Sedan) -- 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 (0.0039 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 transmission clutch hub No. 1.
| 2. INSPECT 2ND GEAR THRUST CLEARANCE |
Using a dial gauge, measure the 2nd gear thrust clearance.
- Standard clearance:
- 0.10 to 0.55 mm (0.0039 to 0.0217 in.)
- Maximum clearance:
- 0.55 mm (0.0217 in.)
If the clearance exceeds the maximum, replace transmission clutch hub No. 1, 2nd gear or 3rd driven gear.
| 3. INSPECT 1ST GEAR RADIAL CLEARANCE |
Using a dial gauge, measure the 1st gear radial clearance between the gear and shaft.
- Standard clearance:
- KOYO made bearing:
- 0.015 to 0.058 mm (0.0006 to 0.0023 in.)
- NSK made bearing:
- 0.015 to 0.056 mm (0.0006 to 0.0022 in.)
- Maximum clearance:
- KOYO made:
- 0.058 mm (0.0023 in.)
- NSK made:
- 0.056 mm (0.0022 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 gauge, measure the 2nd gear radial clearance between the gear and shaft.
- Standard clearance:
- KOYO made:
- 0.015 to 0.058 mm (0.0006 to 0.0023 in.)
- NSK made:
- 0.015 to 0.056 mm (0.0006 to 0.0022 in.)
- Maximum clearance:
- KOYO made:
- 0.058 mm (0.0023 in.)
- NSK made:
- 0.056 mm (0.0022 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 SYNCHRONIZER RING NO.1 (FOR 2ND GEAR) |
Remove synchronizer ring No. 1 from the output shaft.
Using 2 screwdrivers and a hammer, remove the clutch hub No. 1 shaft snap ring from the output shaft.
- HINT:
- Use a piece of cloth to keep the shaft snap ring from flying off.
Using SST and a press, remove the clutch hub No. 1 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 SYNCHRONIZER RING GEAR NO.1 (FOR 1ST GEAR) |
Remove synchronizer ring No. 1 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 transmission clutch hub No. 1.
- NOTICE:
- Use a piece of cloth to keep the shifting key and shifting key spring from flying off.
