Output Shaft For 1st to 4th Gears Assembly Overview
Output Shaft for 1st to 4th Gears Assembly Overview
• Attach transmission to assembly stand. Refer to => [ Transmission, Securing to Assembly Stand ] Transmission, Securing to Assembly Stand.
• If output shaft or tapered roller bearings are replaced, an adjustment on output shaft must be performed. Refer to => [ Output Shaft, 1st to 4th Gears, Adjusting ] Output Shaft, 1st to 4th Gears, Adjusting.
• When installing new gears or a new output shaft, consult technical data. Refer to => [ Code Letters, Assembly Allocation, Ratios and Capacities ] Code Letters, Assembly Allocation, Ratios and Capacities.
• Always replace both tapered roller bearings together as a set.
1 Clutch Housing
2 Oil Deflector Ring
3 Dished Washer
• Pulling out => [ Pull Dished Washer Out of Output Shaft ] Output Shaft, 1st to 4th Gears
• Installing => [ Pressing Dished Washer in Output
Shaft to Stop ] Output Shaft, 1st to 4th Gears
4 Taper Roller Bearing Outer Race
• Pulling out => [ Pulling Out Tapered Roller Bearing
Outer Race ] Output Shaft, 1st to 4th Gears
• Installing => [ Press the Outer Ring for the
Tapered Roller Bearing into the Clutch Housing ] Output Shaft, 1st to 4th Gears
5 Tapered Roller Bearing Inner Race
• Pressing off => [ Pressing Off Inner Race for
Tapered Roller Bearing ] Output Shaft, 1st to 4th Gears
• Pressing on => [ Pressing on Tapered Roller Bearing
Inner Race ] Output Shaft, 1st to 4th Gears
6 Output Shaft
• For 1st to 4th gear
• Adjusting, refer to => [ Output Shaft, 1st to 4th Gears, Adjusting ] Output Shaft, 1st to 4th Gears, Adjusting
7 Needle Bearing
• For 2nd gear
8 2nd Gear Selector Gear
9 Synchronizer ring
• (Inner race for 2nd gear)
• Checking for wear => [ Checking Inner Race for 1st
gear, 2nd Gear and 3rd Gear for Wear ] Output Shaft, 1st to 4th Gears
• Check tabs for scoring
• Installation location => [ Installed Position of Outer
Race, Inner Race and Synchronizer Ring, 2nd Gear ] Output Shaft, 1st to 4th Gears
10 Outer Race for 2nd Gear
• Install on synchronizer ring - 9 -
• Replace if grooved or scored
• Installation location => [ Installed Position of Outer
Race, Inner Race and Synchronizer Ring, 2nd Gear ] Output Shaft, 1st to 4th Gears
11 2nd Gear Synchronizer Ring
• Checking for wear => [ Checking Synchronizer Rings
for 1st, 2nd and 3rd Gears for Wear ] Output Shaft, 1st to 4th Gears
• Installation location => [ Installed Position of Outer
Race, Inner Race and Synchronizer Ring, 2nd Gear ] Output Shaft, 1st to 4th Gears
12 Locking Sleeve with Synchronizer Hub for 1st and 2nd Gears
• After removing circlip - 13 -, press off gear wheel for 2nd gear => [ Pressing Off Locking Collar
and Synchronizer Hub for 1st and 2nd Gears ] Output Shaft, 1st to 4th Gears.
• Disassembling => [ Disassembling and Assembling
Locking Collar and Synchronizer Hub for 1st and 2nd Gears as well as 3rd and
4th Gears ] Output Shaft, 1st to 4th Gears
• Assembling locking collar/synchronizer hub => [ Disassembling and Assembling
Locking Collar and Synchronizer Hub for 1st and 2nd Gears as well as 3rd and
4th Gears ] Output Shaft, 1st to 4th Gears
• Installation location => [ Installation Position of Locking
Collar/Synchronizer Hub for 1st and 2nd Gear ] Output Shaft, 1st to 4th Gears
• Pressing on => [ Pressing on locking Collar/Synchronizer
Hub for 1st and 2nd Gear ] Output Shaft, 1st to 4th Gears
13 Securing Ring
14 Synchronizer Ring for 1st Gear
• Checking for wear => [ Checking Synchronizer Rings
for 1st, 2nd and 3rd Gears for Wear ] Output Shaft, 1st to 4th Gears
• Insert so that holes engage in engagement pieces of locking collar - 12 -
15 Outer Race for 1st Gear
• Insert into synchronizer ring - 14 -, installation position => [ Installation Position of Outer
Ring for 1st and 3rd Gear ] Output Shaft, 1st to 4th Gears
• Replace if grooved or scored
16 Synchronizer Ring
• (Inner race for 1st gear)
• Checking for wear => [ Checking Inner Race for 1st
gear, 2nd Gear and 3rd Gear for Wear ] Output Shaft, 1st to 4th Gears
• Check tabs for scoring
• Installation location => [ Installed Position of Synchronizer
Ring (inner ring for 1st and 3rd gear) ] Output Shaft, 1st to 4th Gears
17 Needle Bearing
• For 1st gear
18 1st Gear Selector Gear
• Installation location => [ Installation Position of Selector
Gear for 1st and 3rd Gear ] Output Shaft, 1st to 4th Gears
19 Thrust Washers
• For 1st and 4th gear
• Quantity: 2
• Insert tab of thrust washer in output shaft hole
20 Securing Ring
• Holds thrust washers - 19 - in position on output shaft
21 Needle Bearing
• For 4th gear
22 4th Gear Selector Gear
23 4th Gear Synchronizer Ring
• Checking for wear => [ Checking Synchronizer Ring for
4th Gear for Wear ] Output Shaft, 1st to 4th Gears
24 Locking Collar with Synchronizer Hub for 3rd and 4th Gear
• After removing circlip - 25 -, pull off gear wheel for 4th gear => [ Pulling Off Synchronizer Hub/Operating
Sleeve for 3rd and 4th Gear with Gear Wheel for 4th Gear ] Output Shaft, 1st to 4th Gears.
• Disassembling => [ Disassembling and Assembling
Locking Collar and Synchronizer Hub for 1st and 2nd Gears as well as 3rd and
4th Gears ] Output Shaft, 1st to 4th Gears
• Installation position of locking collar/synchronizer hub => [ Installation Position of Locking
Collar/Synchronizer Hub for 3rd and 4th Gear ] Output Shaft, 1st to 4th Gears
• Assembling operating sleeve/synchronizer hub => [ Disassembling and Assembling
Locking Collar and Synchronizer Hub for 1st and 2nd Gears as well as 3rd and
4th Gears ] Output Shaft, 1st to 4th Gears and => [ Assembling Locking Collar/Synchronizer
Hub for 1st and 2nd Gears as well as 3rd and 4th Gears ] Output Shaft, 1st to 4th Gears
• Pressing on => [ Pressing on Synchronizer Hub
with Locking Collar for 3rd and 4th Gears ] Output Shaft, 1st to 4th Gears
25 Securing Ring
26 Synchronizer Ring for 3rd Gear
• Checking for wear => [ Checking Synchronizer Rings
for 1st, 2nd and 3rd Gears for Wear ] Output Shaft, 1st to 4th Gears
27 Outer Race for 3rd Gear
• Insert into synchronizer ring - 26 -, installation position => [ Installation Position of Outer
Ring for 1st and 3rd Gear ] Output Shaft, 1st to 4th Gears
• Replace if grooved or scored
28 Synchronizer Ring
• (Inner race for 3rd gear)
• Checking for wear => [ Checking Inner Race for 1st
gear, 2nd Gear and 3rd Gear for Wear ] Output Shaft, 1st to 4th Gears
• Check tabs for scoring
• Installation location => [ Installed Position of Synchronizer
Ring (inner ring for 1st and 3rd gear) ] Output Shaft, 1st to 4th Gears
29 Needle Bearing
• For 3rd gear
30 3rd Gear Selector Gear
• Installation location => [ Installation Position of Selector
Gear for 1st and 3rd Gear ] Output Shaft, 1st to 4th Gears
31 Tapered Roller Bearing Inner Race
• Pulling off => [ Pulling off Inner Race for Tapered
Roller Bearing ] Output Shaft, 1st to 4th Gears
• Pressing on => [ Pressing on Tapered Roller Bearing
Inner Race ] Output Shaft, 1st to 4th Gears
32 Securing Ring
• When replacing tapered roller bearing - 31 - and output shaft - 6 -, determine again
33 Taper Roller Bearing Outer Race
• Pulling out => [ Pulling Outer Race/Tapered Roller
Bearing Out of Transmission Housing ] Output Shaft, 1st to 4th Gears
• Installing => [ Pressing in Tapered Roller Bearing
Outer Race into Transmission Housing ] Output Shaft, 1st to 4th Gears
34 Adjustment Shim
• Determining thickness, refer to => [ Output Shaft, 1st to 4th Gears, Adjusting ] Output Shaft, 1st to 4th Gears, Adjusting
35 Transmission Housing