Output Shaft

Output Shaft





Special Tool(s)








Disassembly

CAUTION: When pressing off components, hold the shaft so that it does not fall.





1. Measure the output shaft clearances.
1. Measure the clearance between first gear and the differential drive gear.
2. Measure the clearance between second gear and secondary third gear.





2. Using the special tools and press, press off the bearing (fourth gear end).





3. Using the special tools and a press, press off the fourth speed gear.





4. Remove the snap ring.





5. Using the special tools and a press, press off the third speed gear and second gear.





6. CAUTION: The synchronizer blocking rings are not interchangeable. Be sure to keep them in the order that they were removed.

Remove the synchronizer blocking ring.





7. Remove the snap ring.





8. CAUTION: The synchronizer blocking rings are not interchangeable. Make sure to keep them in the order that they were removed.

NOTE: Inspect all the synchronizer components for wear and damage.

Using the special tools and a press, press off the synchronizer hub, synchronizer blocking ring, and first gear.





9. Using the special tools and a press, press off the bearing (first gear end).





10. Measure output shaft gear runout.
^ Inspect the output shaft for worn or damaged gears.
^ Inspect the output shaft for clogged oil passage.





11. NOTE: Set the synchronizer ring squarely in the gear, then measure around the circumference.

Inspect the synchronizer blocking ring.
^ Measure the clearance from the side of the gear.
^ Inspect for smooth engagement with the gear.
^ Inspect for worn or damaged teeth or tapered surface.
12. Inspect the synchronizer hub.
^ Inspect for worn or damaged splines, synchronizer insert groove or end surface.
^ Inspect for smooth hub sleeve movement when it is installed.





13. Measure the clearance between the first/second synchronizer hub and its shift fork.

Assembly





1. NOTE: Whenever a bearing has been removed, a new one must be installed.

Using the special tools and a press, press on the bearing (first gear side).





2. NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove and synchronizer hub inserts.

Using the special tools and a press, press on the first gear, synchronizer blocking ring, and reverse gear.





3. Install the snap ring.





4. NOTE: When installing the synchronizer blocking ring, align the synchronizer blocking ring groove and synchronizer hub inserts.

Using the special tools and a press, press on the synchronizer blocking ring, second gear, and third speed gear.





5. Install the snap ring.





6. Using the special tools and a press, press on the fourth speed gear.





7. Using the special tools and a press, press on the bearing (fourth gear side).





8. NOTE: If not within specifications, disassemble and reassemble the output shaft assembly.

Measure the output shaft clearances.
1. Measure the clearance between first gear and the differential drive gear.
2. Measure the clearance between second gear and third gear.