Output Shaft: Service and Repair
DISASSEMBLY
1. INSPECT 1ST AND 2ND GEARS THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance.
Standard clearance:
1st gear: 0.10 - 0.40 mm (0.0039 - 0.0157 inch)
2nd gear: 0.10 - 0.55 mm (0.0039 - 0.0217 inch)
Maximum clearance:
1st gear: 0.40 mm (0.0157 inch)
2nd gear: 0.55 mm (0.0217 inch)
2. INSPECT 1ST AND 2ND GEARS RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance between the gear and shaft.
Standard clearance:
KOYO made
0.015 - 0.058 mm (0.0006 - 0.0023 inch)
NSK made:
0.015 - 0.056 mm (0.0006 - 0.0022 inch)
KOYO made:
0.058 mm (0.0023 inch)
NSK made:
0.056 mm (0.0022 inch)
If the clearance exceeds the maximum, replace the gear, needle roller bearing or shaft.
3. REMOVE REAR BALL BEARING, 4TH DRIVEN GEAR AND OUTPUT GEAR SPACER FROM OUTPUT SHAFT
a) Using SST and a press, remove the rear ball bearing and 4th driven gear.
SST 09950-00020
b) Remove the output gear spacer.
4. REMOVE 3RD DRIVEN GEAR, 2ND GEAR, NEEDLE ROLLER BEARING AND SYNCHRONIZER RING
a) Shift the reverse gear into the 1st gear.
b) Using SST and a press, remove the 3rd driven gear and 2nd gear.
SST 09950-00020
c) Remove the needle roller bearing and synchronizer ring.
5. REMOVE SNAP RING
Using 2 screwdrivers and a hammer, tap out the snap ring.
6. REMOVE REVERSE GEAR ASSEMBLY, 1ST GEAR, SYNCHRONIZER RING, NEEDLE ROLLER BEARING, THRUST WASHER AND BALL
a) Using a press, remove the reverse gear assembly, 1st gear and synchronizer ring.
b) Remove the needle roller bearing, thrust washer and ball.
7. DISASSEMBLE REVERSE GEAR ASSEMBLY
a) Using a screwdriver, remove the 2 shifting key springs and 3 shifting keys from the No. 1 clutch hub.
b) Remove the reverse gear from the No. 1 clutch hub.
INSPECTION
1. INSPECT SYNCHRONIZER RING
a) Check for wear or damage.
b) Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.
If the braking effect is insufficient, apply a small amount of the fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.
NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.
c) Check again the braking effect of the synchronizer ring.
d) Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
Minimum clearance: 0.75 mm (0.0295 inch)
If the clearance is less than the minimum, replace the synchronizer ring and apply a small amount of the fine lapping compound on gear cone.
NOTICE: Ensure the fine lapping compound is completely washed off after rubbing.
2. INSPECT SHIFT FORK AND REVERSE GEAR CLEARANCE
Using a feeler gauge, measure the clearance between the reverse gear and shift fork.
Maximum clearance: 0.35 mm (0.014 inch)
If the clearance exceeds the maximum, replace the shift fork or reverse gear.
3. INSPECT OUTPUT SHAFT
a) Check the output shaft for wear or damage.
b) Using a micrometer, measure the outer diameter of the output shaft journal surface.
Minimum outer diameter:
Part A: 32.985 mm (1.2986 inch)
Part B: 37.985 mm (1.4955 inch)
Part C: 31.985 mm (1.2592 inch)
If the outer diameter is less than the minimum, replace the output shaft.
c) Using a dial indicator, check the shaft runout.
Maximum runout: 0.03 mm (0.0012 inch)
If the runout exceeds the maximum, replace the output shaft.
REASSEMBLY
HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.
1. ASSEMBLE REVERSE GEAR ASSEMBLY
a) Install the 3 shifting keys and reverse gear to the No. 1 clutch hub.
b) Install the 2 shifting key springs under the shifting keys.
NOTICE: Position the shifting key springs so that their end gaps are not in line.
2. INSTALL BALL, THRUST WASHER, NEEDLE ROLLER BEARING, 1ST GEAR, SYNCHRONIZER RING AND REVERSE GEAR ASSEMBLY TO OUTPUT SHAFT
a) Install the ball to the output shaft.
b) Fit the thrust washer groove securely over the locking ball when installing the thrust on the output shaft.
c) Apply gear oil to the needle roller bearing and install it.
d) Install the 1st gear and synchronizer ring.
e) Place the reverse gear assembly and align the synchronizer ring slots with the shifting keys.
f) Using a press, install the reverse gear assembly.
3. INSTALL SNAP RING
a) Select a snap ring that allows the minimum axial play.
b) Using a screwdriver and hammer, tap in the snap ring.
4. INSPECT 1ST GEAR THRUST CLEARANCE
5. INSTALL NEEDLE ROLLER BEARING, SYNCHRONIZER RING, 2ND GEAR AND 3RD DRIVEN GEAR
a) Apply gear oil to the needle roller bearing and install it.
b) Place the synchronizer ring on the reverse gear assembly and align the ring slots with the shifting keys.
c) Install the 2nd gear.
d) Using a press, install the 3rd driven gear.
6. INSPECT 2ND GEAR THRUST CLEARANCE
7. INSTALL OUTPUT GEAR SPACER, 4TH DRIVEN GEAR AND REAR BALL BEARING
a) Install the output gear spacer.
b) Using SST and a press, install the 4th driven gear and rear ball bearing.
SST 09608-00071