Output Gear Disassembly

OUTPUT GEAR DISASSEMBLY





CAUTION: The output shaft assembly is serviced as an assembly. Do not try to repair any component on the output shaft. If the 1/2 synchronizer or gear fails, it is necessary to replace the complete output shaft assembly.

It is necessary to check the synchronizer stop ring gap. Use a feeler gauge to measure the gaps between the stop rings and the speed gears.
The correct gaps are listed below:
1st: 1.04 - 1.72 mm (0.0409 - 0.0677 inch)
2nd: 0.94 - 1.72 mm (0.0370 - 0.0677 inch)
3rd: 1.37 - 1.93 mm (0.0539 - 0.0760 inch)
4th: 1.41 - 1.97 mm (0.0555 - 0.0776 inch)
5th: 1.37 - 1.93 mm (0.0539 - 0.0760 inch)
If a stop ring gap does not fall within the specifications it must be inspected for wear and replaced. If the 1st and 2nd synchronizer stop ring is worn beyond specifications, the complete output shaft assembly must be replaced.
The output shaft incorporates the 1st and 2nd gears and synchronizers on the assembly.