Output Shaft: Service and Repair
NOTE: For removal and installation procedures refer to "Manual Transmission/Transaxle, Service and Repair."OUTPUT SHAFT DISASSEMBLY
1. Inspect 1st and 2nd gears thrust clearance.
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
- 1st gear: 0.10 - 0.40 mm (0.0039 - 0.0157 in.)
- 2nd gear: 0.10 - 0.45 mm (0.0039 - 0.0177 in.)
Maximum clearance:
- 1st gear: 0.45 mm (0.0177 in.)
- 2nd gear: 0.50 mm (0.0197 in.)
2. Inspect 1st and 2nd gears radial clearance.
Using a dial indicator, measure the radial clearance between the gear and shaft.
Standard clearance: 0.015 - 0.058 mm (0.0006 - 0.0023 in.)
Maximum clearance: 0.070 mm (0.0028 in.)
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
3. Remove rear ball bearing, 4th driven gear and output gear spacer from output shaft.
Using SST 09950 - 00020 and a press, remove the rear ball bearing and 4th driven gear.
b. Remove the output near spacer.
4. Remove 3rd driven gear, 2nd gear, needle roller bearing and synchronizer ring.
a. Shift the No.1 hub sleeve into the 1st gear.
b. Using SST 09950 - 00020 and a press, remove the 3rd driven gear and 2nd gear.
c. Remove the needle roller ring bearing and synchronizer
5. Remove snap ring.
Using 2 screwdrivers and a hammer, tap out the snap ring.
6. Remove No.1 hub sleeve assembly, 1st gear, synchronizer ring, needle roller bearing, thrust washer and ball.
a. Using a press, remove the No.1 hub sleeve assembly, 1st gear and synchronizer ring.
Remove the needle roller bearing, thrust washer and ball.
7. Remove No.1 hub sleeve, shifting key and spring from No.1 clutch hub
Using a screwdriver, remove the 3 shifting keys and 2 springs from the No.1 clutch hub.
OUTPUT SHAFT ASSEMBLY
NOTE: Coat all of the sliding and rotating surfaces with gear oil before assembly.
1. Install No.1 clutch hub into hub sleeve.
a. Install the No.1 clutch hub and shifting keys to the No. 1 hub sleeve.
b. Install the shifting key springs under the shifting keys.
NOTE: Position the key springs so that their end gaps are not in line.
2. Install ball, thrust washer, 1st gear, needle roller bearing, synchronizer ring and no.1 hub sleeve assembly to output shaft.
a. install the ball to the shaft.
b. Fit the thrust washer groove securely over the locking ball when installing the thrust on the shaft.
c. Apply gear oil to the needle roller bearing.
d. Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
e. Using a press, install the 1st gear and No. 1 hub sleeve.
3. Install snap ring.
Select a snap ring that will allow minimum axial play.
b. Using a screwdriver and hammer, tap in the snap ring.
4. Inspect 1st gear thrust clearance.
5. Install synchronizer ring, 2nd gear, needle roller bearing and 3rd driven gear.
a. Place the synchronizer ring on the gear and align the ring on the gear and align the ring slots with the shifting keys.
b. Apply gear oil to the needle roller bearing.
c. Install the 2nd gear.
d. Using a press, install the 3rd driven gear.
6. Inspect 2nd gear thrust clearance.
7. Install output gear spacer, 4th driven gear and rear ball bearing.
Install the output gear spacer.
Using SST 09608 - 00071 and a press, install the 4th driven gear and rear ball bearing.