Disassembly

COMPONENTS





DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY

1.-1 (2WD)
REMOVE SPEEDOMETER DRIVE GEAR
(a) Using snap ring pliers, remove the snap ring.
(b) Remove the speedometer drive gear and ball.
(c) Using a magnetic finger, remove the steel ball.
(d) Using snap ring pliers, remove the snap ring.





1.-2 (4WD)
REMOVE SLEEVE FROM OUTPUT SHAFT
Using SST, remove the sleeve from the output shaft.
SST 09950-20017





2. (5-Speed)
REMOVE FIFTH GEAR, REAR BEARING, FIRST GEAR, INNER RACE AND NEEDLE ROLLER BEARING
(a) Using two screwdrivers and a hammer, tap out the snap ring.
(b) Using a press, remove the 5th gear, rear bearing, 1st gear and inner race.
(c) Remove the needle roller bearing.





3. REMOVE SYNCHRONIZER RING
4. REMOVE LOCKING BALL
Using a magnetic finger, remove the locking ball.





5. REMOVE HUB SLEEVE NO.1 ASSEMBLY, SYNCHRONIZER RING, SECOND GEAR AND NEEDLE ROLLER BEARING
(a) Using a press, remove hub sleeve No.1, the synchronizer ring and 2nd gear.
(b) Remove the needle roller bearing.





6. REMOVE HUB SLEEVE NO.1, SHIFTING KEYS AND SPRINGS FROM CLUTCH HUB NO.1
Using a screwdriver, remove the three shifting keys and two springs from clutch hub No.1.





7. REMOVE HUB SLEEVE NO.2 ASSEMBLY, SYNCHRONIZER RING, THIRD GEAR AND NEEDLE ROLLER BEARING
(a) Using snap ring pliers, remove the snap ring.
(b) Using a press, remove hub sleeve No.2, the synchronizer ring and 3rd gear.
(c) Remove the needle roller bearing.





8. REMOVE HUB SLEEVE NO.2, SHIFTING KEYS AND SPRINGS FROM CLUTCH HUB NO.2
Using a screwdriver, remove the three shifting keys and springs from clutch hub No.2.