Output Shaft

Output Shaft

















Disassembly

NOTE: When pressing off components, hold the shaft so it does not fall.

1. Measure the output shaft clearances.

1. Measure the clearance between 1st gear and the differential drive gear. First gear endplay is 0.05-0.33 mm (0.001-0.012 in).

2. Measure the clearance between 2nd gear and secondary 3rd gear. Second gear endplay is 0.18-0.51 mm (0.007-0.02 in).





2. Using the Bearing Puller and a suitable press, press off the bearing and 4th gear.
- Discard the bearing.

- Always install new bearings and cups as a set.





3. Remove and discard the snap ring.





4. Using the Bearing Puller and a suitable press, press off the 3rd gear and 2nd gear.





5. NOTE: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.

Remove the synchronizer blocking ring, the synchronizer inner cone and the synchronizer outer cone.





6. Remove and discard the snap ring.





7. NOTE: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.

Using the Bearing/Oil Seal Plate and a suitable press, press off the synchronizer hub, synchronizer blocking ring and 1st gear.





8. NOTE: Using a paint pen, mark the hub to sleeve position for reassembly.

Disassemble the synchronizer assembly.

1. Remove the synchronizer blocking spring.

2. Rotate the synchronizer and remove the opposite spring.

3. Remove the hub inserts.

4. Separate the synchronizer hub from the sleeve.
- Inspect all synchronizer components for wear or damage. Install a new synchronizer as necessary.





9. NOTE: Always install new bearings and cups as a set.

Using the Bearing Puller and a suitable press, press off the bearing and discard.





10. Using a Dial Indicator Gauge with Holding Fixture, measure the output shaft gear runout.
- Inspect the output shaft for wear or damage.

- Inspect the output shaft for a plugged oil passage.

- Maximum output shaft gear runout is 0.015 mm (0.0006 in).

- Install a new output shaft as necessary.





11. Set the synchronizer ring squarely in the gear, then measure around the circumference.
- Measure the clearance from the side of the gear.
- Synchronizer ring clearance is 0.80-1.50 mm (0.031-0.059 in).

- Inspect for smooth engagement with the gear.

- Inspect for worn or damaged teeth or tapered surface. Install new components as necessary.





12. Inspect the synchronizer hub.
- Inspect for worn or damaged splines, synchronizer insert groove or end surface.

- Inspect for smooth hub sleeve movement when it is installed.

13. Measure the clearance between the 1st/2nd synchronizer hub and its shift fork.
- Shift fork and hub sleeve clearance is 0.10-0.95 mm (0.003-0.037 in).

Assembly

1. NOTE: Do not reassemble the output shaft dry. Apply lubricant throughout the assembly procedure.

Lubricate all output shaft components with the recommended transmission lubricant during reassemble.

2. Using the Bearing/Oil Seal Plate, Transaxle Bearing Cup Installer and a suitable press, press on a new bearing.





3. If installing a new output shaft, using a suitable press, install the new spacer.

4. Install the friction dampener.

5. Assemble the synchronizer.

1. Position the synchronizer hub to the sleeve.

2. Install the hub inserts.

3. Install the blocking spring.

4. Rotate the synchronizer and install the opposite blocking spring.





6. Assemble the 1st gear blocking ring set and synchronizer.

7. NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove and synchronizer hub inserts to prevent damage.

Using the Bearing/Oil Seal Plate, Differential Bearing Cup Installer and a suitable press, press on the 1st gear, the synchronizer blocking ring and synchronizer assembly.





8. Invert the shaft.

9. Install a new snap ring.





10. NOTE: Make sure 1st gear rotates freely.

Install the synchronizer blocking ring, the synchronizer outer cone and the synchronizer inner cone.





11. Install the friction damper cone onto 2nd gear.

12. Install 2nd gear.





13. Using a suitable tool, press on 3rd gear.
- Make sure the slots on 3rd gear are aligned with the fingers on the friction damper cone.





14. NOTE: Make sure 2nd gear rotates freely.

Install a new snap ring.





15. Using a suitable tool, press on 4th gear.





16. NOTICE: Only press on the inner race of the bearing or damage may occur to the bearing.

Invert the output shaft in the press. Using a suitable tool, install a new bearing.

17. NOTE: If not within specifications, disassemble and reassemble the output shaft assembly.

Measure the output shaft clearances.

1. Measure the clearance between 1st gear and the differential drive gear. First gear endplay is 0.05-0.33 mm (0.001-0.012 in).

2. Measure the clearance between 2nd gear and 3rd gear. Second gear endplay is 0.18-0.51 mm (0.007-0.02 in).