Output Shaft Assembly
OUTPUT SHAFTCOMPONENTS:
REMOVAL
1. INSPECT 1ST GEAR THRUST CLEARANCE
a. Using a feeler gauge, measure the thrust clearance.
Standard clearance: 0.25 to 0.40 mm (0.0098 to 0.0157 inch)
If the clearance is out of specification, replace the 1st gear or No. 1 transmission clutch hub.
2. INSPECT 2ND GEAR THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 inch)
If the clearance is out of specification, replace the No. 1 transmission clutch hub, 2nd gear or 3rd driven gear.
3. INSPECT 1ST GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the radial clearance.
Standard clearance:
Standard clearance
If the 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 radial clearance.
Standard clearance:
Standard clearance
If the 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, press out 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, press out the 3rd driven gear and 2nd gear from the output shaft.
SST 09950-00020
8. REMOVE NO. 2 SYNCHRONIZER RING SET
a. Remove the No. 2 synchronizer ring set from the No. 1 transmission clutch hub.
9. REMOVE 2ND GEAR NEEDLE ROLLER BEARING
a. Remove the needle roller bearing from the output shaft.
10. REMOVE 2ND GEAR BEARING SPACER
a. Remove the bearing spacer from the output shaft.
11. REMOVE 2ND GEAR BUSH
a. Remove the bush from the output shaft.
12. REMOVE 2ND GEAR BUSH BALL
a. Using a magnetic finger, remove the bush ball from the output shaft.
13. REMOVE 1ST GEAR
a. Using SST and a press, remove the No. 1 transmission clutch hub and 1st gear from the output shaft.
SST 09950-00020
14. REMOVE NO. 1 SYNCHRONIZER RING SET
a. Remove the No. 1 synchronizer ring set from the 1st gear.
15. REMOVE 1ST GEAR NEEDLE ROLLER BEARING
a. Remove the needle roller bearing from the output shaft.
16. REMOVE FRONT OUTPUT SHAFT BEARING
a. Using SST and a press, press out the 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 No. 1 transmission clutch hub, 3 No. 1 synchromesh shifting keys and 3 No. 1 synchromesh shifting key springs from the reverse gear.
INSTALLATION
1. INSTALL REVERSE GEAR
a. Coat the reverse gear with gear oil.
b. Install the 3 No. 1 synchromesh shifting key springs and No. 1 transmission clutch hub to the reverse gear.
NOTICE: Assemble the reverse gear and the No. 1 transmission clutch hub in the correct direction.
c. Using a screwdriver, install the 3 No. 1 synchromesh shifting keys to the reverse gear.
2. INSTALL FRONT OUTPUT SHAFT BEARING
a. Using SST and a press, press in the front bearing (inner race) to the output shaft.
SST 09950-60010 (09951-00430), 09950-70010 (09951-07150)
3. INSTALL NO. 1 SYNCHRONIZER RING SET
a. Coat the No. 1 synchronizer ring set with gear oil, and install it to the 1st gear.
NOTICE: Align the claw of the No. 1 synchronizer ring set (middle) with the hole of the 1st gear and install it.
4. INSTALL 1ST GEAR NEEDLE ROLLER BEARING
a. Coat the needle roller bearing with gear oil, and install it to the output shaft.
5. INSTALL 1ST GEAR
a. Coat the 1st gear with gear oil, and install it to the output shaft.
6. INSTALL NO. 1 TRANSMISSION CLUTCH HUB
a. Using SST and a press, press in the No. 1 transmission clutch hub to the output shaft.
SST 09316-60011 (09316-00031), 09950-60010 (09951-00320), 09950-70010 (09951-07100)
NOTICE:
^ Align the claw of the No. 1 synchronizer ring set (outer) with the hole of the No. 1 transmission clutch hub and install it.
^ Make sure that the 1st gear rotates.
7. INSTALL 2ND GEAR BUSH BALL
a. Coat the bush ball with MP grease, and install it to the output shaft.
8. INSTALL 2ND GEAR BUSH
a. Coat the bush with gear oil, and install it to the output shaft.
9. INSTALL 2ND GEAR BEARING SPACER
a. Coat the bearing spacer with gear oil, and install it to the output shaft.
10. INSTALL 2ND GEAR NEEDLE ROLLER BEARING
a. Coat the needle roller bearing with gear oil, and install it to the output shaft.
11. INSTALL NO. 2 SYNCHRONIZER RING SET
a. Coat the No. 2 synchronizer ring set with gear oil, and install it to the No. 1 transmission clutch hub.
NOTICE: Align the key groove on the No. 2 synchronizer ring set with the No. 1 synchromesh shifting key.
12. INSTALL 2ND GEAR
a. Coat the 2nd gear with gear oil, and install it to the output shaft.
13. INSTALL 3RD DRIVEN GEAR
a. Using SST and a press, press in the 3rd driven gear to the output shaft.
SST 09608-00071, 09950-60010 (09951-00320), 09950-70010 (09951-07100)
14. INSTALL OUTPUT GEAR SPACER
a. Install the output gear spacer to the output shaft.
15. INSTALL 4TH DRIVEN GEAR
a. Using SST and a press, press in the 4th driven gear to the output shaft.
SST 09608-00071, 09950-60010 (09951-00320), 09950-70010 (09951-07100)
16. INSTALL FRONT OUTPUT SHAFT BEARING
a. Using SST and a press, press in the front bearing (inner race) to the output shaft.
SST 09506-30012, 09950-60010 (09951-00320), 09950-70010 (09951-07100)
17. INSPECT 2ND GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the radial clearance.
Standard clearance:
Standard clearance
If the clearance is out of specification, replace the 2nd gear, 2nd gear bush and 2nd gear needle roller bearing.
18. INSPECT 1ST GEAR RADIAL CLEARANCE
a. Using a dial indicator, measure the radial clearance.
Standard clearance:
Standard clearance
If the clearance is out of specification, replace the 1st gear and 1st gear needle roller bearing.
19. INSPECT 2ND GEAR THRUST CLEARANCE
a. Using a dial indicator, measure the thrust clearance.
Standard clearance: 0.10 to 0.35 mm (0.0039 to 0.0138 inch)
If the clearance is out of specification, replace the No. 1 transmission clutch hub, 2nd gear or 3rd driven gear.
20. INSPECT 1ST GEAR THRUST CLEARANCE
a. Using a feeler gauge, measure the thrust clearance.
Standard clearance: 0.25 to 0.40 mm (0.0098 to 0.0157 inch)
If the clearance is out of specification, replace the 1st gear or No. 1 transmission clutch hub.
INSPECTION
1. INSPECT OUTPUT SHAFT
a. Using a V-block and a dial indicator, inspect the shaft for runout.
Maximum runout: 0.03 mm (0.0012 inch)
If the runout is greater than the maximum, replace the output shaft.
b. Using a micrometer, measure the outside diameter of the output shaft journal surface.
Standard outside diameter:
Standard outside diameter
Minimum outside diameter:
Minimum outside diameter
If the outside diameter is less than the minimum, replace the output shaft.
2. INSPECT 2ND GEAR
a. Using a cylinder gauge, measure the inside diameter.
Standard inside diameter: 50.009 to 50.025 mm (1.9689 to 50.025 inch)
Maximum inside diameter: 50.025 mm (1.9695 inch)
If the inside diameter is greater than the maximum, replace the 2nd gear.
3. INSPECT 1ST GEAR
a. Using a cylinder gauge, measure the inside diameter.
Standard inside diameter: 51.009 to 51.025 mm (51.009 to 51.0525 inch)
Maximum inside diameter: 51.025 mm (2.0089 inch)
If the inside diameter is greater than the maximum, replace the 1st gear.
4. INSPECT NO. 2 SYNCHRONIZER RING SET
a. Coat the 2nd gear cone with gear oil. Turn the No. 2 synchronizer ring set in one direction while pushing it against the No. 2 synchronizer ring set. Check that the ring locks.
If the No. 2 synchronizer ring set does not lock, replace the synchronizer ring or 2nd gear.
b. Check the clearance between the No. 2 synchronizer ring set and 2nd gear while pushing the 2nd gear against the No. 2 synchronizer ring set.
Standard clearance: 0.70 to 1.45 mm (0.0276 to 0.0571 inch)
If the clearance is out of specification, replace the No. 2 synchronizer ring set with a new one.
5. INSPECT NO. 1 SYNCHRONIZER RING SET
a. Coat the 1st gear cone with gear oil. Turn the No. 1 synchronizer ring set in one direction while pushing it against the 1st gear cone. Check that the ring locks. If the No. 1 synchronizer ring set does not lock, replace it with a new one.
b. Check the clearance between the No. 1 synchronizer ring set and 1st gear while pushing the 1st gear against the cone of the No. 1 synchronizer ring set.
Standard clearance: 0.70 to 1.45 mm (0.0276 to 0.0571 inch)
If the clearance is out of specification, replace the No. 1 synchronizer ring set with a new one.
6. INSPECT REVERSE GEAR
a. Using vernier calipers, measure the width of the reverse gear groove (A) and thickness of the claw part on the No. 1 gear shift fork (B), and calculate the clearance.
Standard clearance: A - B = 0.15 to 0.35 mm (0.0276 to 0.0571 inch)
If the clearance is out of specification, replace the reverse gear and No. 1 gear shift fork with new ones.
7. INSPECT NO. 1 TRANSMISSION CLUTCH HUB
a. Check the sliding condition between the No. 1 transmission clutch hub 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 No. 1 transmission clutch hub.