Output Shaft: Service and Repair

Output Shaft And Gears:

Refer to above for parts identification during disassembly and assembly of the output shaft.

DISASSEMBLY

Remove Output Shaft Pilot Bearing:

1. Remove input shaft and output shaft pilot bearing from output shaft, if necessary.

Check Output Shaft Gear Thrust Clearance:

2. Measure and note thrust clearance of output shaft gears. First gear clearance should be 0. 10 - 0.40 mm (0.004 - 0.0197 inch). Second and third gear clearance should be 0.10 - 0.30 mm (0.003 - 0.0118 inch).

Remove Fifth Gear Snap-Ring:

3. Remove output shaft fifth gear snap ring with two screwdrivers.

Remove Fifth Gear, First Gear Bearing, And Thrust Washer:

4. Using Bearing Splitter P-334 or suitable press plates positioned under first gear, press fifth gear, rear bearing, first gear, and first gear thrust washer off output shaft.
5. Remove first gear thrust washer locating pin from output shaft.
6. Remove first gear needle roller bearing from output shaft.
7. Remove first gear spacer from output shaft.
8. Remove first gear synchronizer ring.
9. Remove select fit snap-ring holding the 1-2 synchronizer/reverse gear onto the output shaft.

Remove Second Gear And 1 - 2 Synchronizer/Reverse Gear:

10. Using Bearing Splitter P-334 or suitable press plates positioned under second gear, press 1-2 synchronizer/reverse gear and second gear from output shaft.
11. Remove second gear needle roller bearing from the output shaft or second gear.

Remove 3 - 4 Synchronizer Snap Ring:

12. Remove select fit snap-ring holding the 3-4 synchronizer onto the output shaft.

Remove 3 - 4 Synchronizer And Third Gear:

13. Using Bearing Splitter P-334 or suitable press plates positioned under third gear, press the 3-4 synchronizer and third gear from output shaft.
14. Remove third gear needle roller bearing from output shaft or gear.

ASSEMBLY
1. Lubricate transmission components with specified gear lubricant during assembly.

Synchronizer Identification:

2. If necessary, assemble 1-2 and 3-4 synchronizer hubs, sleeves, springs and key inserts.
3. Install third gear needle bearing onto the output shaft.
4. Install third gear over bearing and onto Output shaft flange.
5. Install third gear synchronizer ring to third gear.
6. Position the 3-4 synchronizer onto the output shaft.
7. Using Adapter 6761 and a shop press, press the 3-4 synchronizer onto the output shaft.

Select 3 - 4 Synchronizer Snap-Ring:

8. Select the thickest snap-ring that will fit into the snap-ring groove of the output shaft.
9. Install snap-ring to hold 3-4 synchronizer onto output shaft.

Check Third Gear Clearance:

10. Verify third gear thrust clearance with feeler gauge. Clearance should be 0.10 - 0.30 mm (0.003 - 0.0118 inch). If clearance is out of specification.
11. Install second gear needle bearing onto output shaft.
12. Install second gear over bearing and onto output shaft flange.
13. Install second gear synchronizer ring onto second gear.
14. Position 1-2 synchronizer/reverse gear assembly onto splines of output shaft.
15. Using Driver MD-998805, Adapter 6761, and a shop press, press the 1-2 synchronizer/reverse gear onto the output shaft.

Second Gear And Synchronizer Assembly:

16. Select the thickest snap-ring that will fit into the snap-ring groove of the output shaft.
17. Install snap-ring to hold 1-2 synchronizer/reverse gear onto output shaft.
18. Install first gear synchronizer ring into 1-2 synchronizer/reverse gear.
19. Install the first gear spacer onto the input shaft and against the 1-2 synchronizer/reverse gear snap-ring.

First And Fifth Gear Components:

20. Install first gear needle bearing onto output shaft.
21. Install first gear onto output shaft and over bearing.
22. Install the first gear thrust washer locating pin into the output shaft.
23. Install the first gear thrust washer onto the output shaft. Rotate the thrust washer until the washer locating pin aligns with the notch in the washer.
24. Position output shaft rear bearing onto output shaft. Ensure that the snap ring groove in bearing outer race is toward rear of output shaft.
25. Using Driver L-4507 and suitable mallet, drive bearing onto output shaft.
26. Install snap-ring onto output shaft rear bearing outer race.

Check First-Second Gear Thrust Clearance:

27. Check first and second gear thrust clearance. First gear clearance should be 0.10 - 0.40 mm (0.003 - 0.0197 inch). Second gear clearance should be 0.10 - 0.30 min (0.003 - 0.0118 inch). If clearance is out of specification.
28. Position fifth gear onto output shaft with the gear's long shoulder toward the rear of shaft. Ensure that the gear and output shaft splines are aligned.
29. Using Adapter 6761, Driver L-4507, and a shop press, press fifth gear onto output shaft.

Select/Install Fifth Gear Snap Ring:

30. Select the thickest snap-ring that will fit into the snap-ring groove of the output shaft.
31. Install snap-ring to hold fifth gear onto output shaft.
32. Install output shaft pilot bearing into the input shaft.
33. Install the input shaft to the output shafts.