Part 2

OUTPUT SHAFT

DISASSEMBLY AND ASSEMBLY
[OUTPUT SHAFT No.2]





Required Special Tools:
* MD998812: Installer cap
* MD998813: Installer 100
* MD998814: Installer 200
* MD998819: Installer adapter
* MD998827: Installer adapter
* MD998917: Bearing remover

DISASSEMBLY





1. Remove the shaft snap ring.





2. Using special tool MD998917, support the 6th gear sub assembly and remove the tapered roller bearing No.2 and 6th gear sub-assembly.





3. Remove the synchronizer outer ring No.3.





4. Remove the needle roller bearing and spacer.





5. Remove the shaft snap ring.





6. Using special tool MD998917, support the 5th gear sub-assembly and remove the 5th-6th hub sleeve, synchronizer outer ring No.3 and 5th gear sub-assembly.





7. Remove the spacer and needle roller bearing.





8. Remove the spacer.





9. Remove the shaft snap ring.





10. Using special tool MD998917, support the reverse gear and remove the reverse synchronizer sub-assembly, synchronizer ring No.4 and reverse gear.
11. Remove the needle roller bearing.





12. Using special tool MD998917, support the tapered roller bearing No.2 and remove the tapered roller bearing No.2.

ASSEMBLY





1. Using special tools MD998812, MD998813, and MD998819, install the tapered roller bearing No.2.





2. Install the needle roller bearing and reverse gear to output shaft No.2.
3. Install the synchronizer ring No.4.





4. As shown in the illustration, install the synchromesh shifting key No.3 and the synchromesh shifting key spring No.3.





5. Install the synchromesh shifting key No.3 to the transmission clutch hub No.4 so that the claw is positioned as shown in the illustration.





6. Combine the transmission clutch hub No.4 with the transmission hub sleeve No.4 in the direction as shown in the illustration.

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





7. Set the reverse synchronizer sub-assembly to the output shaft No.2 in the direction as shown in the illustration.

NOTE:
- Install the reverse synchronizer assembly securely into the stopper of the output shaft No.2.
- Check for smooth rotation of the gear after the installation.





8. Install the synchronizer ring No.4, aligning the projection in the synchronizer hub with the groove in position shown in the illustration.





9. Using special tools MD998812, MD998814 and MD998827, install the reverse synchronizer sub-assembly.

NOTE:
- Confirm correct position as shown.
- The synchronizer ring must not bind.





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





11. Install the spacer to output shaft No.2.





12. Install the needle roller bearing and spacer to output shaft No.2.





13. Install the 5th gear sub-assembly to output shaft No.2, and synchronizer outer ring No.3 to 5th gear sub-assembly.





14. As shown in the illustration, set the 5th-6th hub sleeve.

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





15. Set the 5th-6th hub sleeve to the output shaft No.2 in the direction as shown in the illustration.





16. Using special tools MD998812, MD998814 and MD998827, install the 5th-6th hub sleeve.

NOTE:
- During press fit, confirm correct positions of the hub and the synchronizer ring.
- Install the 5th-6th synchronizer assembly securely into the stopper of the output shaft No.2.
- After installation, confirm the sleeve and the hub slide smoothly.
- The synchronizer ring must not bind.





17. Select a shaft snap ring that allows distance of the thrust crevice of 5th-6th hub to fall within the standard value range.
Standard value: 0 -0.1 mm (0 -0.0039 inch)





18. Install the spacer and needle roller bearing to output shaft No.2.





19. Install the synchronizer outer ring No.3 to 6th gear sub-assembly.





20. Install the 6th gear sub-assembly to output shaft No.2.





21. Using special tools MD998812, MD998813 and MD998819, install the tapered roller bearing No.2.





22. Install the shaft snap ring to output shaft No.2.
Standard value: 0 -0.1 mm (0 -0.0039 inch)