Output Shaft
OUTPUT SHAFTCOMPONENTS:
DISASSEMBLY
1. INSPECT 1ST GEAR THRUST CLEARANCE
(a) 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
(a) 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
(a) 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
(a) 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
(a) 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
(a) Remove the output gear spacer from the output shaft.
7. REMOVE 2ND GEAR
(a) 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
(a) 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)
(a) Remove synchronizer ring No. 1 from the output shaft.
10. REMOVE 1ST GEAR
(a) Using 2 screwdrivers and a hammer, remove the clutch hub No. 1 shaft snap ring from the output shaft.
HINT: Use a shop rag or piece of cloth to keep the shaft snap ring from flying off.
(b) 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)
(a) Remove synchronizer ring No. 1 from the 1st gear.
12. REMOVE 1ST GEAR NEEDLE ROLLER BEARING
(a) Remove the 1st gear needle roller bearing from the output shaft.
13. REMOVE 1ST GEAR THRUST WASHER
(a) Remove the 1st gear thrust washer from the output shaft.
14. REMOVE 1ST GEAR THRUST WASHER PIN OR BALL
(a) Remove the 1st gear thrust washer pin or ball from the output shaft.
15. REMOVE REVERSE GEAR
(a) Remove the reverse gear, 3 synchromesh shifting keys and 3 synchromesh shifting key springs from transmission clutch hub No. 1.
NOTICE: Use a shop rag or piece of cloth to keep the shifting key and shifting key spring from flying off.
INSPECTION
1. INSPECT OUTPUT SHAFT
(a) Using a dial gauge and 2 V-blocks, check the output shaft runout.
Maximum runout: 0.015 mm (0.0006 in.)
If the runout exceeds the maximum, replace the output shaft.
(b) Using a micrometer, measure the outer diameter of the output shaft journal surface, at the locations indicated.
Standard outer diameter:
Part A: 31.985 to 32.000 mm (1.2592 to 1.2598 in.)
Part B: 37.985 to 38.000 mm (1.4955 to 1.4961 in.)
Part C: 32.985 to 33.000 mm (1.2986 to 1.2992 in.)
If the outer diameters are less than the minimums, replace the output shaft.
2. INSPECT 2ND GEAR
(a) Using a cylinder gauge, measure the inside diameter of the 2nd gear.
Standard inside diameter: 38.015 to 38.031 mm (1.4967 to 1.4972 in.)
Maximum inside diameter: 38.031 mm (1.4972 in.)
If the inside diameter exceeds the maximum, replace the 1st gear.
3. INSPECT 1ST GEAR
(a) Using a cylinder gauge, measure the inside diameter of the 1st gear.
Standard inside diameter: 44.015 to 44.031 mm (1.7328 to 1.7335 in.)
Maximum inside diameter: 44.031 mm (1.7335 in.)
If the inside diameter exceeds the maximum, replace the 1st gear.
4. INSPECT 1ST GEAR THRUST WASHER
(a) Using a micrometer, measure the 1st gear thrust washer.
Standard thickness: 5.975 to 6.025 mm (0.2352 to 0.2372 in.)
Minimum thickness: 5.975 mm (0.2352 in.)
If the thickness is less than the minimum, replace the 1st gear thrust washer.
5. INSPECT SYNCHRONIZER RING NO.1 (FOR 2ND GEAR)
(a) Check for wear and damage.
(b) Coat the 2nd gear cone with gear oil.
(c) Turn the synchronizer ring in one direction while pushing it against the 2nd gear cone.
(d) Check that the ring locks.
If the synchronizer ring does not lock, replace the synchronizer ring.
(e) Using a feeler gauge, measure the clearance between the synchronizer ring back and the gear spline end.
Standard clearance: 0.70 to 1.3 mm (0.0276 to 0.0512 in.)
Minimum clearance: 0.70 mm (0.0276 in.)
If the clearance is less than the minimum, replace the synchronizer ring.
6. INSPECT SYNCHRONIZER RING NO.1 (FOR 1ST GEAR)
(a) Check for wear and damage.
(b) Coat the 1st gear cone with gear oil.
(c) Turn the synchronizer ring in one direction while pushing it against the 1st gear cone.
(d) Check that the ring locks.
If the synchronizer ring does not lock, replace the synchronizer ring.
(e) Using a feeler gauge, measure the clearance between the synchronizer ring back and the gear spline end.
Standard clearance: 0.75 to 1.65 mm (0.0295 to 0.0650 in.)
Minimum clearance: 0.75 mm (0.0295 in.)
If the clearance is less than the minimum, replace the synchronizer ring.
7. INSPECT REVERSE GEAR
(a) Using a vernier calipers, measure the width of the reverse gear groove (A) and the thickness of the claw part on the reverse shift fork (B), and calculate the clearance.
Standard clearance (A - B): 0.15 to 0.35 mm (0.0059 to 0.0138 in.)
If the clearance is outside the specifications, replace the reverse gear and reverse shift fork.
8. INSPECT TRANSMISSION CLUTCH HUB NO.1
(a) Check that transmission clutch hub No. 1 and the reverse gear slide smoothly.
(b) Check that the edges of the reverse gear spline gear are not worn down.
REASSEMBLY
1. INSTALL REVERSE GEAR
(a) Coat the reverse gear with gear oil and install it onto transmission clutch hob No. 1.
NOTICE: Orient the reverse gear and transmission clutch hub No. 1 correctly.
(b) Install the 3 synchromesh shifting key springs and 3 synchromesh keys onto transmission clutch hub No. 1.
2. INSTALL 1ST GEAR THRUST WASHER PIN OR BALL
(a) Coat the 1st gear thrust washer pin or ball with MP grease, and install it onto the output shaft.
3. INSTALL 1ST GEAR THRUST WASHER
(a) Coat the 1st gear thrust washer with gear oil and install it onto the output shaft.
4. INSTALL 1ST GEAR NEEDLE ROLLER BEARING
(a) Coat the 1st gear needle roller bearing with gear oil and install it onto the output shaft.
5. INSTALL 1ST GEAR
(a) Coat the 1st gear with gear oil and install it onto the output shaft.
6. INSTALL SYNCHRONIZER RING NO.1 (FOR 1ST GEAR)
(a) Coat synchronizer ring No. 1 with gear oil and install it onto the 1st gear.
7. INSTALL TRANSMISSION CLUTCH HUB NO.1
(a) Using SST and a press, install transmission clutch hub No. 1 onto the output shaft.
SST 09316-60011 (09316-00031)
HINT:
^ The 1st gear can be turned.
^ While checking that the 1st gear thrust washer pin or ball is inserted into the groove of the 1st gear thrust washer, press and fit the clutch hub No. 1.
(b) Select a snap ring that will allow minimum axial play.
Standard clearance: 0.1 mm (0.039 in.) or less
Snap ring thickness:
(c) Using a brass bar and a hammer, install the snap ring onto the output shaft.
NOTICE: Do not damage the journal surface of the output shaft.
8. INSTALL 2ND GEAR NEEDLE ROLLER BEARING
(a) Coat the 2nd gear needle roller bearing and 2nd gear bearing spacer with gear oil, and install them onto the output shaft.
9. INSTALL SYNCHRONIZER RING NO.1 (FOR 2ND GEAR)
(a) Coat synchronizer ring No. 1 with gear oil and install it onto the 2nd gear.
10. INSTALL 2ND GEAR
(a) Coat the 2nd gear with gear oil and install it onto the output shaft.
11. INSTALL 3RD DRIVEN GEAR
(a) Using SST and a press, install the 3rd driven gear onto the output shaft.
SST 09316-60011 (09316-00031)
12. INSTALL OUTPUT GEAR SPACER
(a) Install the output gear spacer onto the output shaft.
13. INSTALL 4TH DRIVEN GEAR
(a) Using SST and a press, install the 4th driven gear onto the output shaft.
SST 09612-22011
14. INSTALL OUTPUT SHAFT REAR BEARING
(a) Using SST and a press, install the output shaft rear bearing onto the output shaft.
SST 09612-22011
15. INSPECT 2ND GEAR RADIAL CLEARANCE
(a) 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 0.00023 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.
16. INSPECT 1ST GEAR RADIAL CLEARANCE
(a) Using a dial gauge, measure the 1st gear radial clearance between the gear and shaft.
Standard clearance:
KOYO made: 0.015 to 0.058 mm (0.0006 to 0.00023 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 1st gear or 1st gear needle roller bearing.
17. INSPECT 2ND GEAR THRUST CLEARANCE
(a) 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, the 2nd gear or 3rd driven gear.
18. INSPECT 1ST GEAR THRUST CLEARANCE
(a) 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.