Output Shaft Assembly

OUTPUT SHAFT ASSEMBLY (E350 TRANSAXLE)
OVERHAUL





1. INSPECT 1ST GEAR THRUST CLEARANCE
a. Using a feeler gauge, measure the 1st gear thrust clearance.
Standard clearance: 0.25 to 0.40 mm (0.0098 to 0.0157 inch)
If clearance is out of specification, replace the 1st gear or transmission clutch hub No.1.





2. INSPECT 2ND GEAR THRUST CLEARANCE
a. Using a dial indicator, measure the 2nd gear thrust clearance.
Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 inch)
If clearance is out of specification, replace the transmission clutch hub No.1, 2nd gear or 3rd driven gear.





3. INSPECT 1ST GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the 1st gear radial clearance.





Standard clearance: mm (in.)

If clearance is out of specification, replace the 1st gear and 1st gear needle roller bearing.





4. INSPECT 2ND GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the 2nd gear radial clearance.





Standard clearance: mm (in.)

If clearance is out of specification, replace the 2nd gear, 2nd gear bush and 2nd gear needle roller bearing.





5. REMOVE 4TH DRIVEN GEAR
a. Using SST and a press, remove the output shaft rear bearing (inner race) and 4th driven gear.
SST 09950-00020





6. REMOVE OUTPUT GEAR SPACER
a. Remove the output gear spacer from the output shaft.





7. REMOVE 2ND GEAR
a. Using SST and a press, remove the 3rd driven gear and 2nd gear from the output shaft.
SST 09950-00020





8. REMOVE SYNCHRONIZER RING SET NO.2
a. Remove the synchronizer ring set No.2 from the transmission clutch hub No.1.





9. REMOVE 2ND GEAR NEEDLE ROLLER BEARING
a. Remove the 2nd gear needle roller bearing from the output shaft.





10. REMOVE 2ND GEAR BEARING SPACER
a. Remove the 2nd gear bearing spacer from the output shaft.





11. REMOVE 2ND GEAR BUSH
a. Remove the 2nd gear bush from the output shaft.





12. REMOVE 2ND GEAR BUSH BALL
a. Using a magnetic finger, remove the 2nd gear bush ball from the output shaft.





13. REMOVE 1ST GEAR
a. Using SST and a press, remove the transmission clutch hub No.1 and 1st gear from the output shaft.
SST 09950-00020





14. REMOVE SYNCHRONIZER RING SET NO.1
a. Remove the synchronizer ring set No.1 from the 1st gear.





15. REMOVE 1ST GEAR NEEDLE ROLLER BEARING
a. Remove the 1st gear needle roller bearing from the output shaft.





16. REMOVE OUTPUT SHAFT FRONT BEARING
a. Using SST and a press, remove the output shaft front bearing (inner race) from the output shaft.
SST 09950-00020, 09950-60010 (09951-00320), 09950-70010 (09951-07150)

NOTICE: Do not overtighten the SST.





17. REMOVE REVERSE GEAR
a. Remove the transmission clutch hub No.1, 3 synchromesh shifting keys No.1 and 3 synchromesh shifting key springs No.1 from the reverse gear.





18. INSPECT OUTPUT SHAFT
a. Using a V-block and a dial indicator, inspect the shaft for runout.
Maximum run out: 0.03 mm (0.0012 inch)
If runout exceeds the maximum, replace the output shaft.





b. Using a micrometer, measure the outside diameter of the output shaft journal surface.





Outside diameter: mm (in.)

If the outside diameter is less than the minimum, replace the output shaft.





19. INSPECT 2ND GEAR
a. Using a cylinder gauge, measure the inside diameter of the 2nd gear.





Inside diameter: mm (in.)

If the inside diameter exceeds the maximum, replace the 2nd gear.





20. INSPECT 1ST GEAR
a. Using a cylinder gauge, measure the inside diameter of the 1st gear.





Inside diameter mm (inch)

If the inside diameter exceeds the maximum, replace the 1st gear.





21. INSPECT SYNCHRONIZER RING SET NO.2
a. Coat the 2nd gear cone with gear oil. Turn the synchronizer ring set No.2 in one direction while pushing it against the synchronizer ring set No.2. Check that the ring locks.
If the synchronizer ring set No.2 does not lock, replace the synchronizer ring or 2nd gear.





b. Check the clearance between the synchronizer ring set No.2 and 2nd gear while pushing the 2nd gear against the synchronizer ring set No.2.
Standard clearance: 0.70 to 1.45 mm (0.0276 to 0.0571 inch)
If clearance is out of specification, replace the synchronizer ring set No.2 with a new one.





22. INSPECT SYNCHRONIZER RING SET NO.1
a. Coat the 1st gear cone with gear oil. Turn the synchronizer ring set No.1 in one direction while pushing it against the 1st gear cone. Check that the ring locks.
If the synchronizer ring set No.1 does not lock, replace it with a new one.





b. Check the clearance between the synchronizer ring set No.1 and 1st gear while pushing the 1st gear against the cone of the synchronizer ring set No.1.
Standard clearance: 0.70 to 1.45 mm (0.0276 to 0.0571 inch)
If clearance is out of specification, replace the synchronizer ring set No.1 with a new one.





23. INSPECT REVERSE GEAR
a. Using vernier calipers, measure the width of the reverse gear groove (A) and thickness of the claw part on the gear shift fork No.1 (B), and calculate the clearance.
Standard clearance: 0.15 to 0.35 mm (0.0059 to 0.0138 inch) {A-B}
If clearance is out of specification, replace the reverse gear and gear shift fork No.1 with new ones.





24. INSPECT TRANSMISSION CLUTCH HUB NO.1
a. Check the sliding condition between the transmission clutch hub No.1 and the reverse gear.
b. Check the tip of the spline gear on the sleeve of the reverse gear for wear.
If any defects are found, replace the reverse gear or the transmission clutch hub No.1.





25. INSTALL REVERSE GEAR
a. Coat the reverse gear with gear oil.
b. Install the 3 synchromesh shifting key spring No.1 and transmission clutch hub No.1 to the reverse gear.

NOTICE: Assemble the reverse gear and the transmission clutch hub No.1 in the correct direction.

c. Using a screwdriver, install the 3 synchromesh sifting key No.1 to the reverse gear.





26. INSTALL OUTPUT SHAFT FRONT BEARING
a. Using SST and a press, install the output shaft front bearing (inner race) to the output shaft.
SST 09950-60010 (09951-00430), 09950-70010 (09951-07150)





27. INSTALL SYNCHRONIZER RING SET NO.1
a. Coat the synchronizer ring set No.1 with gear oil, and install it to the 1st gear.

NOTICE: Align the claw of the synchronizer ring set No.1 (middle) with the hole of the 1st gear and install.





28. INSTALL 1ST GEAR NEEDLE ROLLER BEARING
a. Coat the 1st gear needle roller bearing with gear oil, and install it to the output shaft.





29. INSTALL 1ST GEAR
a. Coat the 1st gear with gear oil, and install it to the output shaft.





30. INSTALL TRANSMISSION CLUTCH HUB NO.1
a. Using SST and a press, install the transmission clutch hub No.1 to the output shaft.
SST 09316-60011 (09316-00031), 09950-60010 (09951-00320), 09950-70010 (09951-07100)

NOTICE:
- Align the claw of the synchronizer ring set No.1 (outer) with the hole of the transmission clutch hub No.1 and install.
- Make sure that the 1st gear rotates.





31. INSTALL 2ND GEAR BUSH BALL
a. Coat the 2nd gear bush ball with MP grease, and install it to the output shaft.





32. INSTALL 2ND GEAR BUSH
a. Coat the 2nd gear bush with gear oil, and install it to the output shaft.





33. INSTALL 2ND GEAR BEARING SPACER
a. Coat the 2nd gear bearing spacer with gear oil, and install it to the output shaft.





34. INSTALL 2ND GEAR NEEDLE ROLLER BEARING
a. Coat the 2nd gear needle roller bearing with gear oil, and install it to the output shaft.





35. INSTALL SYNCHRONIZER RING SET NO.2
a. Coat the synchronizer ring set No.2 with gear oil, and install it to the transmission clutch hub No.1.

NOTICE: Align the key groove on the synchronizer ring set No.2 with the synchromesh shifting key No.1.





36. INSTALL 2ND GEAR
a. Coat the 2nd gear with gear oil, and install it to the output shaft.





37. INSTALL 3RD DRIVEN GEAR
a. Using SST and a press, install the 3rd driven gear to the output shaft.
SST 09608-00071, 09950-60010 (09951-00320), 09950-70010 (09951-07100)





38. INSTALL OUTPUT GEAR SPACER
a. Install the output gear spacer to the output shaft.





39. INSTALL 4TH DRIVEN GEAR
a. Using SST and a press, install the 4th driven gear to the output shaft.
SST 09608-00071, 09950-60010 (09951-00320), 09950-70010 (09951-07100)





40. INSTALL OUTPUT SHAFT FRONT BEARING
a. Using SST and a press, install the output shaft front bearing (inner race) to the output shaft.
SST 09506-30012, 09950-60010 (09951-00320), 09950-70010 (09951-07100)





41. INSPECT 2ND GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the 2nd gear radial clearance.





Standard clearance: mm (inch)

If clearance is out of specification, replace the 2nd gear, 2nd gear bush and 2nd gear needle roller bearing.





42. INSPECT 1ST GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the 1st gear radial clearance.





Standard clearance: mm (in.)

If clearance is out of specification, replace the 1st gear and 1st gear needle roller bearing.





43. INSPECT 2ND GEAR THRUST CLEARANCE
a. Using a dial indicator, measure the 2nd gear thrust clearance.
Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 inch)
If clearance is out of specification, replace the transmission clutch hub No.1, 2nd gear or 3rd driven gear.





44. INSPECT 1ST GEAR THRUST CLEARANCE
a. Using a feeler gauge, measure the 1st gear thrust clearance.
Standard clearance: 0.25 to 0.40 mm (0.0098 in. to 0.0157 inch)
If clearance is out of specification, replace the 1st gear or transmission clutch hub No.1.