Output Shaft Disassembly

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.20 to 0.45 mm (0.00788 to 0.0177 in.)

Using a dial indicator, measure the thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Using a feeler gauge, measure the thrust clearance.

Standard clearance:

0.10 to 0.25 mm (0.00394 to 0.00984 in.)

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.020 to 0.073 mm (0.00079 to 0.00287 in.)

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.015 to 0.068 mm (0.00059 to 0.00267 in.)

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.015 to 0.068 mm (0.00059 to 0.00267 in.)

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

SST

09950-00020

Remove synchronizer ring (for 1st gear) 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 off 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 together with the reverse gear, No. 1 synchronizer ring set (for 2nd gear) and 2nd gear from the output shaft.

SST

09950-00020

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 together with the No. 2 transmission hub sleeve, No. 2 synchronizer ring and 3rd gear from the output shaft.

SST

09950-00020

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 at point A, B and C shown in the illustration, and measure the runout of the output shaft.

Maximum runout:

0.03 mm (0.00118 in.)

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

Standard Outside Diameter:

Item	Specified Condition
Journal A	38.979 to 38.995 mm (1.5347 to 1.5352 in.)
Journal B	46.984 to 47.000 mm (1.8498 to 1.8503 in.)
Journal C	37.984 to 38.000 mm (1.4955 to 1.4960 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 1.7338 in.)

Maximum inside diameter:

44.040 mm (1.7338 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 (1.8117 to 1.8125 in.)

Maximum inside diameter:

46.040 mm (1.8125 in.)

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

Standard thickness:

5.95 to 6.05 mm (0.235 to 0.238 in.)

Minimum thickness:

5.95 mm (0.235 in.)

Apply gear oil to the cone of the 1st gear, and check that it does not turn in either direction while pushing the No. 1 synchronizer ring set.

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

Standard clearance:

0.65 to 1.75 mm (0.0256 to 0.0688 in.)

Apply gear oil to the cone of the 2nd gear, and check that it does not turn in either direction while pushing the No. 1 synchronizer ring set.

Push the No. 1 synchronizer ring set against 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 0.0688 in.)

Apply gear oil to the cone of the 3rd gear, and check that it does not turn in either direction while pushing the No. 2 synchronizer ring (for the 3rd gear).

Push the No. 2 synchronizer ring against the cone of the 3rd gear. Measure the clearance between the No. 2 synchronizer ring (for the 3rd gear) and 3rd gear.

Standard clearance:

0.75 to 1.65 mm (0.0296 to 0.0649 in.)

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

Standard clearance:

0.15 to 0.41 mm (0.00591 to 0.0161 in.)

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

Check 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 (0.00591 to 0.0137 in.)

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

Check the spline gear of the No. 2 hub sleeve for wear.