Part 1

OUTPUT SHAFT

DISASSEMBLY AND ASSEMBLY
[OUTPUT SHAFT No.1]








Required Special Tools:
* MB990560: Rear axle shaft bearing remover
* MD998812: Installer cap
* MD998813: Installer 100
* MD998814: Installer 200
* MD998820: Installer adapter
* MD998824: Installer adapter
* MD998917: Bearing remover

DISASSEMBLY





1. Remove the shaft snap ring.





2. Using special tool MD998917, support the radial ball bearing and remove the radial ball bearing.





3. Remove the 3rd gear sub-assembly.





4. Remove the spacer, needle roller bearing and synchronizer ring set No.1.





5. Remove the shaft snap ring.





6. Using special tool MD998917, support the 4th gear sub-assembly and remove the 3rd-4th hub sleeve, synchronizer ring set No.4 and 4th gear sub-assembly.





7. Remove the needle roller bearing.





8. Remove the spacer.





9. Remove the shaft snap ring.





10. Remove the 2nd gear bearing inner race.





11. Remove the 2nd gear and needle roller bearing.





12. Remove the synchronizer ring set No.1.





13. Remove the ball.





14. Using special tool MD998917, support the 1st gear and remove the 1st-2nd hub sleeve, synchronizer ring set No.1 and 1st gear.





15. Remove the needle roller bearing.
16. Remove the shaft snap ring.





17. Using special tool MB998917, support the cylindrical roller bearing and remove the cylindrical roller bearing.

ASSEMBLY





1. Using special tools MD998812, MD998813 and MD998820, install the cylindrical roller bearing.

NOTE: Apply the gear oil sufficiently on the sliding surface.





2. Install the shaft snap ring to output shaft No.1.





3. Install the 1st gear and needle roller bearing to output shaft No.1.











4. Install the synchronizer ring set No.1 to 1st gear.

NOTE: Apply the gear oil sufficiently on the sliding surface.





5. As shown in the illustration, set the 1st-2nd hub sleeve.

NOTE:
- Apply gear oil to the caulked area between the sleeve and the hub.
- After installation, confirm the sleeve and the hub slide smoothly.





CAUTION:
- Pay attention to the direction of inserting the 1st-2nd hub sleeve.
- During press fit, confirm correct positions of the hub and the synchronizer ring.
- Check for smooth rotation of the gear after installation.
- The synchronizer ring must not bind.

6. Install the 1st-2nd hub sleeve to the output shaft No.1 in the direction as shown in the illustration.





7. Using special tools MD998812, MD998814 and MD998824, install the 1st-2nd hub sleeve.

NOTE: Install st-2nd hub sleeve securely into the stopper of the output shaft No.1.





8. Insert the ball to the output shaft No.1.

NOTE: Do not forget to attach the ball.





9. Install the synchronizer ring set No.1 to 1st-2nd hub sleeve.





10. Insert the 2nd gear and needle roller bearing to the output shaft No.1.





11. Fit the ball into groove as shown in the illustration.





12. Select a shaft snap ring that allows distance of the thrust crevice of 2nd gear bearing inner race to fall within the standard value range.
Standard value: 0 -0.1 mm (0 -0.0039 inch)





13. Install the snap ring.





14. Insert the spacer to the output shaft No.1.





15. Insert the needle roller bearing to the output shaft No.1.





16. Insert the 4th gear sub-assembly and synchronizer ring set No.4 to the output shaft No.1.





17. As shown in the illustration, set the 3rd-4th hub sleeve.

NOTE:
- Apply gear oil to the caulked area between the sleeve and the hub.
- After installation, confirm the sleeve and the hub slide smoothly.





CAUTION:
- Pay attention to the direction of inserting the 3rd-4th hub sleeve.
- During press fit, confirm correct positions of the hub and the synchronizer ring.
- Check for smooth rotation of the gear after the installation.
- The synchronizer ring must not bind.

18. Set the 3rd-4th hub sleeve to the output shaft No.1 in the direction as shown in the illustration.





19. Using special tools MD998812, MD998813 and MD998824, install the 3rd-4th hub sleeve.





20. Select a shaft snap ring that allows distance of the thrust crevice of 3rd-4th hub to fall within the standard value range.
Standard value: 0 -0.1 mm (0 -0.0039 inch)





21. Install the snap ring.





22. Insert the synchronizer ring set No.1, needle roller bearing and spacer to the 3rd-4th hub sleeve.





23. Insert the 3rd gear sub-assembly to the output shaft No.1.





24. Using special tools MD998812, MD998813 and MD998824, install the radial ball bearing.





25. Select a shaft snap ring that allows distance of the thrust crevice of bearing to fall within the standard value range.
Standard value: 0 -0.1 mm (0 -0.0039 inch)