Output Shaft

OUTPUT SHAFT





COMPONENTS

DISASSEMBLY





1. Remove the taper roller bearing, fourth output gear, spacer, third output gear, second speed gear assembly with second gear sleeve and needle roller bearing, first speed gear assembly with needle roller bearing and spacer and steel ball using the special tool (09432-33200).





2. Remove the rear taper roller bearing using the special tool (09432-21400).

CAUTION: Do not reuse the bearing removed from the shaft.

INSPECTION
OUTPUT SHAFT
1. Check the outer surface of the output shaft where the needle bearing is mounted for damage or abnormal wear [portion (A)].





2. Check the splines for damage or wear.

NEEDLE ROLLER 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 the internal surface for damage, wear or broken grooves.





3. Push the synchronizer ring toward the clutch gear and check clearance "A". Replace if it is not within specifications.
Limit: 0.5 mm (0.02 inch)

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.

SYNCHRONIZER KEY AND SPRING
1. Check for wear of the synchronizer key center protrusion.





2. Check the spring for weakness, distortion or damage.

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 first speed gear assembly with needle bearing.





2. Combine the first - second gear synchronizer hub and sleeve.





3. The synchronizer sleeve has teeth missing at six places.
Assemble the hub to the sleeve so that the center tooth between the two missing teeth will touch the synchronizer key.





4. Install the synchronizer spring so that its protrusion may be engaged in the groove of the synchronizer keys.

CAUTION: When installing the synchronizer springs, make sure they are not facing the same direction.





5. Install the first - second speed gear synchronizer assembly over the output shaft using the special tool(O9432 - 22000).

CAUTION:
- When installing the synchronizer assembly, make sure that the three synchronizer keys are seated correctly in their respective groove on the synchronizer ring.
- After installation of the synchronizer assembly check that first gear rotates smoothly.





6. Install the second speed gear with needle roller bearing and bearing sleeve using the special tool (09432-22000).





7. Install the third speed gear and spacer.





8. Install the fourth speed gear using the special tool (09432-22000).





9. Install the bearing using the special tool(O943222000).

CAUTION; Do not reuse the bearing removed from the shaft.





10. Install the rear side taper roller bearing using the special tool (09432-22000).