Output Shaft ASSY (C60): 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: Measuring 1st Gear Thrust Clearance

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1. Using a dial indicator, measure the 2nd gear thrust clearance.
   1. Standard clearance:0.10 - 0.55 mm (0.0039 - 0.0217 in.) 

Fig 2: Measuring 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 center 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 2nd gear bearing spacer from the output shaft.

Fig 11: Removing 2nd Gear Bearing Spacer

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

Fig 12: Removing Synchronizer Ring Set No. 2

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1. Using 2 screwdrivers and a hammer, remove the clutch hub No. 1 shaft snap ring from the output shaft.
   NOTE: Using a waste to prevent the snap ring from being scattered.
   Fig 13: Removing Clutch Hub No. 1 Shaft 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 14: Removing 1st Gear

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

Fig 15: Removing Synchronizer Ring No. 1

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

Fig 16: Removing 1st Gear Needle Roller Bearing

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

Fig 17: Removing 1st Gear Thrust Washer

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

Fig 18: Removing 1st Gear Thrust Washer Pin Or Ball

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1. Using 2 screwdrivers, remove the output shaft front bearing snap ring.
2. Using SST and a press, remove the output shaft front bearing from the output shaft.

   SST 09950-00020

Fig 19: Removing Output Shaft Front Bearing

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

Fig 20: 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.) 

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

   Fig 21: Measuring Output Shaft Runout

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2. Using a micrometer, measure the outer diameter of the output shaft journal surface.

Fig 22: Output Shaft Outer Diameter Specifications

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Outer diameter: 

Fig 23: Measuring Outer Diameter Of Output Shaft Journal Surface

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If the outer diameter is less than the minimum, replace the output shaft.

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

Fig 24: 2nd Gear Inside Diameter Specifications

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Inside diameter: 

Fig 25: Measuring Inside Diameter Of 2nd Gear

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

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

Fig 26: 1st Gear Inside Diameter Specifications

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Inside diameter: 

Fig 27: Measuring Inside Diameter Of 1st Gear

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

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

Fig 28: 1st Gear Thrust Washer Thickness Specifications

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Thickness: 

Fig 29: Measuring Thickness Of 1st Gear Thrust Washer

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If the thickness is less than 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.

   Fig 30: 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 31: 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.

   Fig 32: 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 33: 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, measure the clearance between reverse gear and shift fork.
   1. Standard clearance:0.15 - 0.35 mm (0.0059 - 0.0138 in.) 

Fig 34: Measuring Clearance Between Reverse Gear And Shift Fork

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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 slides smoothly.
2. Check that the spline gear's edges of the reverse gear is not worn down.

Fig 35: 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.
   NOTE: Do not 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.

Fig 36: Installing Reverse Gear

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

   SST 09223-50010

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

Fig 37: Installing Output Shaft Front Bearing

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

Fig 38: 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 39: 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 40: 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 41: Installing 1st Gear

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

Fig 42: 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 09309-36100 (09309-03610), 09950-60010 (09951-00450)

   Fig 43: Installing Transmission Clutch Hub No. 1

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   NOTE: The 1st gear can be turned.
2. Select a snap ring that will allow minimum axial play.
   1. Standard clearance: 0.1 mm (0.004 in.) or less 
   Fig 44: Snap Ring Thickness Specifications

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   Snap ring thickness: 

   Fig 45: Installing Snap Ring To The 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 bearing spacer with gear oil, install it to the output shaft.

Fig 46: Installing 2nd Gear Bearing Spacer

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

Fig 47: 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 48: Installing Synchronizer Ring Set No. 2

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

Fig 49: 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 50: Installing 3rd Driven Gear

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

Fig 51: 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 52: Installing 4th Driven Gear

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

   SST 09612-22011

Fig 53: Installing Output Shaft Center Bearing

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

Fig 54: 2nd Gear Radial Clearance Specifications

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Standard clearance: 

Fig 55: 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 56: 1st Gear Radial Clearance Specifications

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Standard clearance: 

Fig 57: 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 - 0.55 mm (0.0039 - 0.0217 in.) 

Fig 58: 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 59: Measuring 1st Gear Thrust Clearance

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