Output Shaft and Bearing

Output Shaft and Bearing













Disassembly

1. Remove the following components:

1. The bearing outer snap ring.

2. The 3rd/4th synchronizer spacer.

3. The thrust bearing.





2. NOTE: Press off 3rd/4th synchronizer.

Remove the following components:

1. The 3rd/4th synchronizer.

2. The 3rd gear blocking ring.

3. The 3rd gear.

4. The 3rd gear needle bearing.





3. NOTICE: Make sure that the output shaft flange does not contact the press cradle. Incorrect positioning may result in component damage.

Position the output shaft in a press. Press off the output shaft center bearing, the 1st gear, the 1st/2nd synchronizer assembly and the 2nd gear.





Assembly

1. Using the Dial Indicator Gauge with Holding Fixture, check the output shaft runout.
- Check runout in several places along the output shaft. If runout exceeds 0.05 mm (0.001 in) install a new output shaft.





2. Inspect the synchronizer blocking rings for correct contact with the cone surface of 1st gear.





3. Inspect the synchronizer blocking rings for wear on 2nd gear.
- Vehicles equipped with the 2.3L engine have dual cone blocking rings. Measure both blocking rings.

- If clearance is less than specification, install a new blocking ring or gear.





4. Assemble the 1st and 2nd gear assembly as follows.

1. Install the 2nd gear needle bearing.

2. Install the 2nd gear.

3. Install the 2nd synchronizer blocking ring.
- Vehicles equipped with the 2.3L engine have a dual cone blocking ring.

4. Install the 1st gear synchronizer blocking ring.

5. Install the 1st gear.

6. Install the 1st gear needle bearing.

7. Install the input bearing spacer.

8. Position the output shaft center bearing.





5. Using the Bearing/Oil Seal Plate, Drive Pinion Bearing Cone Installer and the Bearing Tube Remover/Installer, press the output shaft center bearing into place.





6. NOTE: If necessary, use press to install the 3rd/4th synchronizer.

Install the following components:

1. The 3rd gear needle bearing.

2. The 3rd gear.

3. The 3rd gear blocking ring.

4. The 3rd/4th synchronizer.





7. Install the following components:

1. The thrust bearing.

2. The 3rd/4th synchronizer spacer.

3. The bearing outer snap ring.





8. Check the 3rd/4th clutch hub end play.
- If clearance is not within specification, select the correct bearing outer snap ring.

Bearing Outer Snap Ring Select Chart