Output Shaft ASSY (C59): Overhaul

1. Using a feeler gauge, measure the 1st gear thrust clearance.
   1. Standard clearance:0.10 - 0.40 mm (0.0039 - 0.0157 in.) 

Fig 1: Inspecting 1st Gear Thrust Clearance

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1. Using a dial indicator, measure the 2nd gear thrust clearance.
   1. Standard clearance:0.10 - 0.45 mm (0.0039 - 0.0177 in.) 

Fig 2: Inspecting 2nd Gear Thrust Clearance

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

Fig 3: 1st Gear Radial Clearance Specifications

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Standard clearance: 

Fig 4: Measuring 1st Gear Radial Clearance

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If the clearance is out of specification, replace the 1st gear needle roller bearing.

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

Fig 5: 2nd Gear Radial Clearance Specifications

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Standard clearance: 

Fig 6: Measuring 2nd Gear Radial Clearance

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If the clearance is out of specification, replace the 2nd gear needle roller bearing.

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

   SST 09950-00020

Fig 7: Removing 4th Driven Gear

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1. Remove the output gear spacer from the output shaft.

Fig 8: Removing Output Gear Spacer

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

   SST 09950-00020

Fig 9: Removing 2nd Gear

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1. Remove the 2nd gear needle roller bearing from the output shaft.

Fig 10: Removing 2nd Gear Needle Roller Bearing

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1. Remove the synchronizer ring set No. 2 from the output shaft.

Fig 11: Removing Synchronizer Ring Set No. 2

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1. Using 2 screwdrivers and a hammer, tap out the snap ring.
   NOTE:

   Using a waste to prevent the snap ring from being scattered.

   Fig 12: Removing Snap Ring

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2. Using SST and a press, remove the transmission clutch hub No. 1 with 1st gear from the output shaft.

   SST 09950-00020

Fig 13: Removing 1st Gear

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1. Remove the synchronizer ring No. 1 from the 1st gear.

Fig 14: Removing Synchronizer Ring No. 1

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

Fig 15: Removing 1st Gear Needle Roller Bearing

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1. Remove the 1st gear thrust washer from the output shaft.

Fig 16: Removing 1st Gear Thrust Washer

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

Fig 17: Removing 1st Gear Thrust Washer Pin Or Ball

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1. Remove the 3 synchromesh shifting keys, 3 synchromesh shifting key springs and reverse gear.

Fig 18: Removing Reverse Gear

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1. Using a dial indicator and 2 V-blocks, measure the shaft runout.
   1. Maximum runout: 0.015 mm (0.0006 in.) 
   Fig 19: Measuring Output Shaft Runout

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   If the runout exceeds the maximum, replace the output shaft.

2. Using a micrometer, measure the outer diameter of the output shaft journal surface.
   1. Outer diameter: 
      1. Part A: 31.985 mm (1.2592 in.) 
      2. Part B: 37.985 mm (1.4955 in) 
      3. Part C: 32.985 mm (1.2986 in) 

Fig 20: Measuring Outer Diameter Of Output Shaft Journal Surface

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If the outer diameter is below the minimum, replace the output shaft.

1. Using a cylinder gauge, measure the inside diameter of the 2nd gear.

Fig 21: 2nd Gear Inside Diameter Specifications

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Inside diameter: 

Fig 22: Measuring Inside Diameter Of 2nd Gear

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If the inside diameter exceeds the maximum, replace the 2nd gear.

1. Using a cylinder gauge, measure the inside diameter of the 1st gear.

Fig 23: 1st Gear Inside Diameter Specifications

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Inside diameter: 

Fig 24: Measuring Inside Diameter Of The 1st Gear

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If the inside diameter exceeds the maximum, replace the 1st gear.

1. Using a micrometer, measure the thickness of 1st gear thrust washer.

Fig 25: 1st Gear Thrust Washer Thickness Specifications

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Thickness: 

Fig 26: Measuring Thickness Of 1st Gear Thrust Washer

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If the thickness is below the minimum, replace the 1st gear thrust washer.

1. Coat the 2nd gear cone with gear oil.

   Check the braking effect of the synchronizer ring set No. 2.

   Fig 27: Inspecting Synchronizer Ring Set No. 2

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2. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
   1. Standard clearance: 0.7 - 1.3 mm (0.0276 - 0.0512) 

Fig 28: Measuring Clearance Between Synchronizer Ring Back And Gear Spline End

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If the clearance is out of specification, replace the synchronizer ring set No. 2.

1. Coat the 1st gear cone with gear oil.

   Check the braking effect of the synchronizer ring No. 1.

   Fig 29: Inspecting Synchronizer Ring No. 1

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2. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.
   1. Standard clearance: 0.75 - 1.65 mm (0.0295 - 0.065) 

Fig 30: Measuring Clearance Between Synchronizer Ring Back And Gear Spline End

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If the clearance is out of specification, replace the synchronizer ring No. 1.

1. Using a vernier caliper gauge, measure the clearance between reverse gear and shift fork.
   1. Standard clearance:0.15 - 0.35 mm (0.0059 - 0.0138 in.) 

Fig 31: Inspecting Reverse Gear

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If the clearance is out of specification, replace the reverse gear and reverse shift fork.

1. Check that the transmission clutch hub No. 1 and reverse gear sub-assy slides smoothly.
2. Check that the spline gear's edges of the reverse gear sub-assy is not worn down.

Fig 32: Inspecting Transmission Clutch Hub No. 1

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1. Coat the reverse gear with gear oil, install it to the transmission clutch hub No. 1.
   Fig 33: Installing Reverse Gear

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   NOTE: Be sure to set the reverse gear and transmission clutch hub No. 1 in incorrect orientation.
2. Using a screwdriver, install the 3 synchromesh shifting key springs and 3 synchromesh shifting keys.

1. Using SST and a press, install the output shaft front bearing (inner race) to the output shaft.

   SST 09223-50010

   Fig 34: Installing Output Shaft Front Bearing

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2. Select a snap ring from the table below that will make the thrust clearance of the output shaft front bearing (inner race) below 0.1 mm (0.004 in.).
   Fig 35: Output Shaft Front Bearing Snap Ring Thickness Specifications

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   Snap ring thickness: 

   Fig 36: Installing Snap Ring

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3. Using a brass bar and a hammer, tap in the snap ring.

1. Coat the 1st gear thrust washer pin or ball with MP grease, install it to the output shaft.

Fig 37: Installing 1st Gear Thrust Washer Pin Or Ball

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1. Coat the 1st gear thrust washer with gear oil, install it to the output shaft.

Fig 38: Installing 1st Gear Thrust Washer

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1. Coat the 1st gear needle roller bearing with gear oil, install it to the output shaft.

Fig 39: Installing 1st Gear Needle Roller Bearing

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1. Coat the 1st gear with gear oil, install it to the output shaft.

Fig 40: Installing 1st Gear

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1. Coat the synchronizer ring No. 1 with gear oil, install it to the 1st gear.

Fig 41: Installing Synchronizer Ring No. 1

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1. Using SST and a press, install the transmission clutch hub No. 1 to the output shaft.

   SST 09316-60011 (09316-00031)

   NOTE: The 1st gear can be turned.
   Fig 42: Installing Transmission Clutch Hub No. 1

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2. Select a snap ring from the table below that will make the thrust clearance of the transmission clutch hub No. 1 below 0.1 mm (0.004 in.).
   Fig 43: Transmission Clutch Hub No. 1 Snap Ring Thickness Specifications

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   Snap ring thickness: 

   Fig 44: Installing Snap Ring To Output Shaft

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3. Using a brass bar and a hammer, install the snap ring to the output shaft.

1. Coat the 2nd gear needle roller bearing with gear oil, install it to the output shaft.

Fig 45: Installing 2nd Gear Needle Roller Bearing

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1. Coat the synchronizer ring set No. 2 with gear oil, install it to the 2nd gear.

Fig 46: Installing Synchronizer Ring Set No. 2

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1. Coat the 2nd gear with gear oil, install it to the output shaft.

Fig 47: Installing 2nd Gear

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1. Using SST and a press, install the 3rd driven gear to the output shaft.

   SST 09309-36100 (09309-03610), 09608-00071, 09950-60010 (09951-00450)

Fig 48: Installing 3rd Driven Gear

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1. Install the output gear spacer to the output shaft.

Fig 49: Installing Output Gear Spacer

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1. Using SST and a press, install 4th driven gear to the output shaft.

   SST 09612-22011

Fig 50: Installing 4th Driven Gear

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1. Using SST and a press, install output shaft rear bearing to the output shaft.

   SST 09612-22011

Fig 51: Installing Output Shaft Rear Bearing

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

Fig 52: 2nd Gear Radial Clearance Specifications

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Standard clearance: 

Fig 53: Measuring 2nd Gear Radial Clearance

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If the clearance is out of specification, replace the 2nd gear needle roller bearing.

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

Fig 54: 1st Gear Radial Clearance Specifications

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Standard clearance: 

Fig 55: Measuring 1st Gear Radial Clearance

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If the clearance is out of specification, replace the 1st gear needle roller bearing.

1. Using a dial indicator, measure the 2nd gear thrust clearance.
   1. Standard clearance:0.10-0.45 mm (0.0039 - 0.0177 in.) 

Fig 56: Measuring 2nd Gear Thrust Clearance

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1. Using a feeler gauge, measure the 1st gear thrust clearance.
   1. Standard clearance:0.10 - 0.40 mm (0.0039 - 0.0157 in.) 

Fig 57: Measuring 1st Gear Thrust Clearance

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