Output Shaft

Output Shaft

Special Tools:

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 1st gear and the differential drive gear. First gear endplay is 0.05-0.33 mm (0.002-0.013 inch).
2. Measure the clearance between 2nd gear and secondary 3rd gear. Second gear endplay is 0.18-0.51 mm (0.007-0.20 inch).

2. Using the special tools, press off the bearing and 4th gear.
- Discard the bearing.
- Always install new bearings and cups as a set. Do not install one without the other.

3. Remove and discard the snap ring.

4. Using the special tools, press off the 3rd gear and 2nd gear.

5. 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, the synchronizer inner cone and the synchronizer outer cone.

6. Remove and discard the snap ring.

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

Using the special tools, press off the synchronizer hub, synchronizer blocking ring and 1st gear.

8. Disassemble the synchronizer assembly.
1. Remove the synchronizer blocking spring.
2. Rotate the synchronizer and remove the opposite spring.
3. Remove the hub inserts.
4. Separate the synchronizer hub from the sleeve.
^ Inspect all synchronizer components for wear or damage. Install a new synchronizer as necessary.

9. Using the special tools, press off the bearing.
- Discard the bearing.
- Always install new bearings and cups as a set. Do not install one without the other.

10. Measure the output shaft gear runout.
- Inspect the output shaft for wear or damage.
- Inspect the output shaft for a clogged oil passage.
- Maximum output shaft gear runout is 0.015 mm (0.0006 inch).
- Install an output shaft gear as necessary.

11. Set the synchronizer ring squarely in the gear, then measure around the circumference.
- Measure the clearance from the side of the gear.
^ Synchronizer ring clearance is 0.80-1.50 mm (0.031-0.059 inch).
- Inspect for smooth engagement with the gear.
- Inspect for worn or damaged teeth or tapered surface. Install new components as necessary.

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 1st/2nd synchronizer hub and its shift fork.
- Shift fork and hub sleeve clearance is 0.10-0.45 mm (0.004-0.017 inch).

Assembly

1. CAUTION: Do not reassemble the output shaft dry. Apply lubricant throughout the assembly procedure.

Lubricate all output shaft components with the recommended transmission lubricant during reassemble.
2. Using the special tools, press on a new bearing.

3. Assemble the synchronizer.
1. Position the synchronizer hub to the sleeve.
2. Install the hub inserts.
3. Install the blocking spring.
4. Rotate the synchronizer and install the opposite blocking spring.

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

Using the special tools, press on the 1st gear, the synchronizer blocking ring and reverse gear.

5. Install a new snap ring.

6. Install the synchronizer blocking ring, the synchronizer outer cone and the synchronizer inner cone.

7. Install 2nd gear.

8. Install the friction damper cone.

9. Using a suitable driver, press on 3rd gear.
- Make sure the slots on 3rd gear are aligned with the fingers on the friction damper cone.

10. Install a new snap ring.

11. Using a suitable driver, press on 4th gear.

12. Rotate the output shaft in the press. Using the special tools, install a new bearing.

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

Measure the output shaft clearances.
1. Measure the clearance between 1st gear and the differential drive gear.
2. Measure the clearance between 2nd gear and 3rd gear.