Output Shaft: Service and Repair
DISASSEMBLEPositioning output Shaft For Component Replacement:
1. Position output shaft front flange as shown, then remove pilot bearing, snap ring, needle bearing, and front spacer.
Output Shaft Components:
2. Position front (short side of flange) of output shaft facing upward, then lift off clutch hub and sleeve assembly (3rd/4th), synchronizer ring (3rd) and needle bearing as an assembly.
Removing Output Shaft Components:
3. Position output shaft with rear end facing upward on a suitable press as shown.
4. Press off center bearing, 1st gear sleeve, 1st gear, needle bearing, 1st/2nd clutch hub, and sleeve assembly, 1st/2nd synchronizer rings, 2nd gear, and needle bearing as an assembly, using a suitable tool.
ASSEMBLE
Output Shaft Components:
1. Position output shaft with long side of flange facing upward, then position output shaft components to facilitate installation as shown in the Exploded View Of Output Shaft image.
2. Assemble 2nd gear needle bearing, 2nd gear, 2nd gear synchronizer ring, 1st/2nd clutch hub and sleeve assembly, 1st gear synchronizer ring, 1st gear needle bearing, 1st gear, 1st gear sleeve, and center bearing onto shaft.
NOTE: When installing 1st/2nd clutch hub and sleeve, ensure smaller width of sleeve is facing front side of 2nd gear.
3. Press components onto shaft, using bearing replacer tool No. T53T-4621-B and bearing plate tool No. T75L-1165-B or equivalent and a suitable press.
4. Ensure center bearing race is installed into transmission case, then install center bearing onto output shaft.
5. Position output shaft with short side of shaft facing upward on a suitable press, then install 3rd gear needle bearing, 3rd gear, and 3rd gear synchronizer ring.
6. Install 3rd/4th clutch hub and sleeve as follows:
a. Mate clutch hub synchronizer key groove with reference mark on clutch hub sleeve.
b. Ensure mark is facing rearward.
c. Install longer flange on clutch hub sleeve toward 3rd gear.
Installing 3rd/4th Clutch Hub:
NOTE: Front and rear sides of clutch are similar except for reference mark on one side.
7. Install in order, spacer, needle bearing with rollers upward, retaining ring, then the pilot roller bearing.
8. Install original retaining ring.
Measuring Clutch Hub.:
9. Check clutch hub endplay, using a suitable feeler gauge.
3rd/4th Clutch Hub Selective Retaining Ring Chart:
10. If necessary, adjust 3rd/4th clutch hub endplay to specifications. Endplay should be 0.0-0.0019 inch. If endplay is not as specified, select a suitable retaining ring from the 3rd/4th Clutch Hub Selective Retaining Ring Chart that will bring end play to within specifications.