Disassembly of Output Shaft Assembly

1. MEASURE FIRST AND SECOND GEAR THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
1st gear 0.10 - 0.35 mm (0.0039 - 0.0138 in.)
2nd gear 0.10 - 0.45 mm (0.0039 - 0.0177 in.)
Maximum clearance:
1st gear 0.40 mm (0.0157 in.)
2nd gear 0.50 mm (0.0197 in.)




2. CHECK OIL CLEARANCE OF FIRST AND SECOND GEAR
Using dial indicator, measure the oil clearance between the gear and shaft.
Standard clearance:
1st gear 0.009 - 0.051 mm (0.0004 - 0.0020 in.)
2nd gear 0.009 - 0.053 mm (0.0004 - 0.0021 in.)
Maximum clearance:
1st and 2nd gear 0.070 mm (0.0028 in.)
If the clearance exceeds the limit, replace the gear, needle roller bearing or shaft.




3. REMOVE OUTPUT SHAFT REAR BEARING, FOURTH DRIVEN GEAR AND SPACER
a. Using a press, remove the bearing and 4th driven gear.
b. Remove the spacer.




4. REMOVE THIRD DRIVEN GEAR AND SECOND GEAR
Using a press, remove the 3rd driven gear and 2nd gear.
5. REMOVE NEEDLE ROLLER BEARINGS, SPACER AND SYNCHRONIZER RING




6. REMOVE SNAP RING
Using snap ring pliers, remove the snap ring.




7. REMOVE NO.1 HUB SLEEVE ASSEMBLY AND FIRST GEAR
Using a press, remove No.1 hub sleeve and 1st gear.
8. REMOVE SYNCHRONIZER RING AND NEEDLE ROLLER BEARING