Disassembly

C59 MANUAL TRANSMISSION / TRANSAXLE: OUTPUT SHAFT: DISASSEMBLY

1. INSPECT 1ST GEAR THRUST CLEARANCE

(a) Using a feeler gauge, measure the 1st gear thrust clearance.





Standard clearance:

0.10 to 0.40 mm (0.00394 to 0.0157 in.)

Maximum clearance:

0.40 mm (0.0157 in.)

(b) If the clearance exceeds the maximum, replace the 1st gear thrust washer, 1st gear or No. 1 transmission clutch hub.

2. INSPECT 2ND GEAR THRUST CLEARANCE

(a) Using a dial indicator, measure the 2nd gear thrust clearance.





Standard clearance:

0.10 to 0.55 mm (0.00394 to 0.0217 in.)

Maximum clearance:

0.55 mm (0.0217 in.)

(b) If the clearance exceeds the maximum, replace the No. 1 transmission clutch hub, 2nd gear or 3rd driven gear.

3. INSPECT 1ST GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 1st gear radial clearance.





Standard clearance:

NSK made bearing
0.015 to 0.056 mm (0.000591 to 0.00220 in.)

KOYO made bearing
0.015 to 0.058 mm (0.000591 to 0.00228 in.)

Maximum clearance:

NSK made bearing
0.056 mm (0.00220 in.)

KOYO made bearing
0.058 mm (0.00228 in.)

(b) If the clearance exceeds the maximum, replace the 1st gear, 1st gear needle roller bearing or output shaft.

4. INSPECT 2ND GEAR RADIAL CLEARANCE

(a) Using a dial indicator, measure the 2nd gear radial clearance.





Standard clearance:

NSK made bearing
0.015 to 0.056 mm (0.000591 to 0.00220 in.)

KOYO made bearing
0.015 to 0.058 mm (0.000591 to 0.00228 in.)

Maximum clearance:

NSK made bearing
0.056 mm (0.00220 in.)

KOYO made bearing
0.058 mm (0.00228 in.)

(b) If the clearance exceeds the maximum, replace the 2nd gear, 2nd gear needle roller bearing or output shaft.

5. REMOVE 4TH DRIVEN GEAR

(a) Using SST and a press, remove the output shaft rear bearing and 4th driven gear from the output shaft.





SST : 09950-00020

6. REMOVE OUTPUT GEAR SPACER

(a) Remove the output gear spacer from the output shaft.





7. REMOVE 2ND GEAR

(a) Using SST and a press, remove the 3rd driven gear with the 2nd gear from the output shaft.





SST : 09950-00020

8. REMOVE 2ND GEAR NEEDLE ROLLER BEARING

(a) Remove the 2nd gear needle roller bearing and 2nd gear bearing spacer from the output shaft.





9. REMOVE NO. 2 SYNCHRONIZER RING SET (FOR 2ND GEAR)

(a) Remove the No. 2 synchronizer ring set from the output shaft.





10. REMOVE 1ST GEAR

(a) Using 2 screwdrivers and a hammer, remove the No. 1 clutch hub shaft snap ring from the output shaft.





HINT
Use a piece of cloth to keep the shaft snap ring from flying off.

(b) Using SST and a press, remove the No. 1 clutch hub assembly and 1st gear from the output shaft.





SST : 09950-00020

NOTICE:
* Do not tighten SST excessively.
* Support the output shaft by hand to prevent it from dropping off.
11. REMOVE NO. 1 SYNCHRONIZER RING SET (FOR 1ST GEAR)

(a) Remove the No. 1 synchronizer ring set from the 1st gear.





12. REMOVE 1ST GEAR NEEDLE ROLLER BEARING

(a) Remove the 1st gear needle roller bearing from the output shaft.





13. REMOVE 1ST GEAR THRUST WASHER

(a) Remove the 1st gear thrust washer from the output shaft.





14. REMOVE 1ST GEAR THRUST WASHER PIN OR BALL

(a) Remove the 1st gear thrust washer pin or ball from the output shaft.





15. REMOVE REVERSE GEAR

(a) Remove the reverse gear, 3 synchromesh shifting keys, and 3 synchromesh shifting key springs from the No. 1 transmission clutch hub.





NOTICE:
Use a piece of cloth to keep the shifting keys and shifting key springs from flying off.