Output Shaft Assembly

COMPONENTS

DISASSEMBLY OF OUTPUT SHAFT ASSEMBLY
1. REMOVE OUTPUT SHAFT CENTER BEARING AND FIRST GEAR ASSEMBLY
(a) Shift hub sleeve No.1 onto the 2nd gear.
(b) Using a press, remove the center bearing, 1st gear, needle roller bearing, inner race and synchronizer ring.

2. REMOVE LOCKING BALL
Using a magnetic finger, remove the locking ball.

3. REMOVE NO.1 HUB SLEEVE ASSEMBLY, SECOND GEAR AND NEEDLE ROLLER BEARING
Using a press, remove the parts from the shaft as an assembly.

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

5. REMOVE NO.2 HUB SLEEVE ASSEMBLY AND THIRD GEAR
(a) Using snap ring pliers, remove the snap ring.

(b) Using a press, remove No.2 hub sleeve, synchronizer ring and 3rd gear.

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

INSPECTION OF OUTPUT SHAFT ASSEMBLY
1. MEASURE EACH GEAR THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance of each gear.
Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 in.)
Maximum clearance:
0.30 mm (0.0118 in.)

2. MEASURE EACH GEAR OIL CLEARANCE
Using a dial indicator, measure the oil clearance of each gear.
Standard clearance:
1st and 2nd gear
0.009 - 0.060 mm (0.0004 - 0.0024 in.)
3rd gear
0.060 - 0.103 mm (0.0024 - 0.0041 in.)
Maximum clearance:
1st and 2nd gear
0.15 mm (0.0059 in.)
3rd gear
0.20 mm (0.0079 in.)
If the clearance exceeds the limit, replace the gear, shaft or needle roller bearing.

3. INSPECT SYNCHRONIZER RINGS
(a) Turn the ring and push it in to check the braking action.

(b) Measure the clearance between the synchronizer ring back and the gear spline end.
Standard clearance:
0.7 - 1.7 mm (0.028 - 0.067 in.)
Minimum clearance:
0.5 mm (0.020 in.)
If the clearance is less than the limit, replace the synchronizer ring.

4. MEASURE CLEARANCE OF SHIFT FORKS AND HUB SLEEVES
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the limit, replace the shift fork or hub sleeve.

5. INSPECT OUTPUT SHAFT AND INNER RACE
(a) Using calipers, measure the output shaft flange thickness.
Minimum thickness: 5.60 mm (0.2205 in.)

(b) Using calipers, measure the inner race flange thick- ness.
Minimum thickness: 4.76 mm (0.1874 in.)

(c) Using micrometer, measure the outer diameter of the output shaft journal.
Minimum diameter:
2nd gear 42.835 mm (1.6841 in.)
3rd gear 37.80 mm (1.4882 in.)

(d) Using micrometer, measure the outer diameter of the inner race.
Minimum diameter: 42.855 mm (1.6872 in.)

(e) Using a dial indicator, check the shaft runout.
Maximum runout: 0.06 mm (0.0024 in.)

ASSEMBLY OF OUTPUT SHAFT ASSEMBLY
1. INSERT CLUTCH HUB NO.1 AND NO.2 INTO HUB SLEEVE
(a) Install the clutch hub and shifting keys to the hub sleeve.
(b) Install the shifting key springs under the shifting keys.
NOTICE: Install the key springs positioned so that their end gaps are not in line.

2. INSTALL THIRD GEAR AND CLUTCH HUB NO.2 ON OUTPUT SHAFT
(a) Apply gear oil to the shaft.
(b) Place the synchronizer ring on the gear and align the ring slots with the shifting keys.

3. INSTALL SNAP RING
Select a snap ring that will allow minimum axial play, and install it on the shaft.

4. MEASURE THIRD GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 3rd gear thrust clearance.
Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 in.)

5. INSTALL SECOND GEAR AND CLUTCH HUB NO.1
(a) Apply gear oil to the shaft and needle roller bearing.
(b) Place the synchronizer ring on the gear and align the ring slots with the shifting keys.
(c) Install the needle roller bearing in the 2nd gear.

(d) Using a press, install the 2nd gear and clutch hub No.1.

6. MEASURE SECOND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the 2nd gear thrust clearance.
Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 in.)

7. INSTALL LOCKING BALL AND FIRST GEAR ASSEMBLY
(a) Install the locking ball in the shaft.
(b) Apply gear oil to the bearing.
(c) Assemble the 1st gear, synchronizer ring, needle roller bearing and bearing inner race.

(d) Install the assembly on the output shaft with the synchronizer ring slots aligned with the shifting keys and turn the inner race to align it with the locking ball.

8. INSTALL OUTPUT SHAFT CENTER BEARING
Using SST and a press, install the bearing on the output shaft with the outer race snap ring groove toward the rear.
HINT: Hold the 1st gear inner race to prevent it from falling.
SST 09506-35010

9. MEASURE FIRST GEAR THRUST CLEARANCE Using a feeler gauge, measure the 1st gear thrust clearance.
Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 in.)