Output Shaft

OUTPUT SHAFT





COMPONENTS

DISASSEMBLY





1. Remove the taper bearing and the reverse gear using the special tool (03495-33000).





2. Remove the synchronizer ring, synchronizer spring (5th & Rev), sleeve (5th & Rev).





3. Remove the synchronizer hub and the 5th gear using the special tool (03495-33000).





4. Remove the 4th, 3rd, 2nd, 1st gear all together the special tool (09432-33200).

INSPECTION
OUTPUT SHAFT





1. Check the outer surface of where the needle bearing is mounted for damage or abnormal wear.
2. Check the splines for damage or wear.

NEEDLE BEARING





1. Install the needle bearing on the shaft with the bearing sleeve and gear. Check that it rotates smoothly without abnormal noise or play.
2. Check the needle bearing cage for distortion.

SYNCHRONIZER RING





1. Check the clutch gear teeth for damage.
2. Check internal surface for damage, wear or broken grooves.

SYNCHRONIZER SLEEVE AND HUB





1. Install the synchronizer sleeve on the hub and check that it slides smoothly.
2. Check that the sleeve is free from damage.
3. Check for wear of the hub end surfaces (in contact with each gear).

CAUTION: Replace the synchronizer hub and sleeve as a set.

GEARS





1. Check the helical gear and clutch gear teeth for damage or wear.
2. Check the gear cone for rough surfaces, damage or wear.
3. Check the gear bore for damage or wear.

REASSEMBLY





1. Install the needle roller bearing.





2. Install the 1st speed gear.





3. Install the triple cone assembly.





4. Install the synchronizer sleeve and hub.





5. Install the triple cone assembly.





6. Install the 2nd speed sleeve and the needle roller bearing.





7. Install the 2nd and 3rd speed gear with all together above mentioned using the special tool (09432-22000).





8. Install the snap ring.





9. Install the 4th speed gear, the 5th speed gear sleeve, the needle roller bearing, the 5th speed gear, the synchronizer ring (5th), the synchronizer hub and the sleeve (5 & R).





10. Install the needle roller bearing, the reverse gear assembly and the reverse driven gear sleeve.





11. Install the taper bearing with all together above mentioned using the special tool (09432-22000).