Rear Output Shaft

DISASSEMBLY





1. INSPECT OUTPUT SHAFT FRONT NEEDLE ROLLER BEARING
a) Install the input shaft assembly via the needle roller bearing to the rear output shaft assembly.
b) Rotate the input shaft assembly and inspect the needle roller bearing. Check that there should be no abnormal resistance, catching, abnormal noise or rattling.





2. INSPECT DRIVE SPROCKET THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance of the drive sprocket.
Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 inch)
Maximum clearance: 0.25 mm (0.0098 inch)
If the clearance exceeds the maximum, replace the drive sprocket.





3. INSPECT DRIVE SPROCKET RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance of the drive sprocket.
Standard clearance: 0.01 - 0.06 mm (0.0004 - 0.0024 inch)
Maximum clearance: 0.06 mm (0.0024 inch)
If the clearance exceeds the maximum, replace the drive sprocket, rear output shaft or needle roller bearing.





4. REMOVE HIGH AND LOW CLUTCH SLEEVE
a) Using a snap ring expander, remove the clutch hub snap ring.
b) Remove the No. 2 spacer and input gear stopper ball.
c) Remove the high and low clutch sleeve.





5. REMOVE CLUTCH HUB AND CENTER DIFFERENTIAL LOCK SLEEVE





6. REMOVE OUTPUT SHAFT RADIAL BALL BEARING
Using SST, remove the output shaft radial ball bearing.
SST 09950-00020, 09950-00030, 09950-40011 (09957-04010)
7. REMOVE DRIVE SPROCKET AND FRONT DRIVE CLUTCH SLEEVE ASSEMBLY





a) Remove the No.1 spacer, output shaft spacer ball, needle roller bearing, drive sprocket and front drive clutch sleeve assembly.





b) Remove the front drive clutch sleeve from the drive sprocket.
c) Using a screwdriver, remove the 2 shifting key springs.
d) Remove the 3 shifting keys.





8. REMOVE SYNCHRONIZER INNER RING, SYNCHRONIZER CENTER RING AND SYNCHRONIZER OUTER RING FROM CENTER DIFFERENTIAL PLANETARY GEAR ASSEMBLY
9. REMOVE CENTER DIFFERENTIAL PLANETARY GEAR ASSEMBLY





a) Remove the center differential planetary gear assembly from the rear output shaft.





b) Using a screwdriver, remove the center differential planetary ring gear snap ring.





c) Remove the center differential planetary ring gear and No.1 center differential planetary gear washer from the center differential planetary gear.

INSPECTION





1. INSPECT HIGH AND LOW CLUTCH SLEEVE AND NO. 2 GEAR SHIFT FORK CLEARANCE
a) Using vernier calipers, measure the thickness of the No. 2 gear shift fork claw.
Thickness: 11.85 mm (0.4665 inch)
b) Using vernier calipers, measure the groove of the high and low clutch sleeve.
Distance: 12.00 mm (0.4724 inch)
c) Calculate a clearance between the high and low clutch sleeve and No. 2 gear shift fork clearance.
Standard clearance: 0.15 - 0.35 mm (0.0059 - 0.0138 inch)
Maximum clearance: 0.35 mm (0.138 inch)
If the clearance exceeds the maximum, replace the high and low clutch sleeve or No. 2 gear shift fork.





2. INSPECT CLUTCH HUB AND HIGH AND LOW CLUTCH SLEEVE
a) Check that the tip of the spline gear of the high and low clutch sleeve is not worn.
b) Install the high and low clutch sleeve to the clutch hub and check that the high and low clutch sleeve moves smoothly.





3. INSPECT CENTER DIFFERENTIAL LOCK SLEEVE AND CENTER DIFFERENTIAL LOCK FORK
a) Using vernier calipers, measure the thickness of the center differential lock fork claw.
Thickness: 10.2 mm (0.4016 inch)
b) Using vernier calipers, measure the groove of the center differential lock sleeve.
Distance: 10.5 mm (0.4134 inch)
c) Calculate a clearance between the center differential lock sleeve and center differential lock fork.
Standard clearance: 0.26 - 0.84 mm (0.0102 - 0.0331 inch)
Maximum clearance: 0.84 mm (0.0331 inch)
If the clearance exceeds the maximum, replace the center differential lock sleeve or center differential lock fork.





4. INSPECT CENTER DIFFERENTIAL LOCK SLEEVE AND CLUTCH HUB
a) Check that the tip of the spline gear of the center differential lock sleeve is not worn.
b) Install the center differential lock sleeve to the clutch hub and check that the center differential lock sleeve moves smoothly.





5. INSPECT FRONT DRIVE CLUTCH SLEEVE AND NO.1 GEAR SHIFT FORK
a) Using vernier calipers, measure the thickness of the No.1 gear shift fork claw.
Thickness: 11.85 mm (0.4665 inch)
b) Using vernier calipers, measure the groove of the front drive clutch sleeve.
Distance: 12.00 mm (0.4724 inch)
c) Calculate a clearance between the front drive clutch sleeve and No.1 gear shift fork.
Standard clearance: 0.15 - 0.35 mm (0.0059 - 0.0138 inch)
Maximum clearance: 0.35 mm (0.0138 inch)
If the clearance exceeds the maximum, replace the front drive clutch sleeve or No.1 gear shift fork.





6. INSPECT DRIVE SPROCKET AND FRONT DRIVE CLUTCH SLEEVE
a) Check that the tip of the spline gear of the front drive clutch sleeve is not worn.
b) Install the front drive clutch sleeve to the drive sprocket and check that the front drive clutch sleeve moves smoothly.





7. INSPECT REAR OUTPUT SHAFT
Using a micrometer, measure the outer diameter of the rear output shaft journal surface.
Standard diameter:
Part A: 36.98 - 37.00 mm (1.4559 - 1.4567 inch)
Part B: 27.98 - 27.99 mm (1.1016 - 1.1020 inch)
Minimum diameter:
Part A: 36.98 mm (1.4559 inch)
Part B: 27.98 mm (1.1016 inch)
If the outer diameter is less than the minimum, replace the rear output shaft.





8. INSPECT CENTER DIFFERENTIAL PLANETARY GEAR RADIAL CLEARANCE
Using a dial indicator, measure the radial clearance of the pinion gear (outside and inside).
Standard clearance: 0.01 - 0.04 mm (0.0004 - 0.0016 inch)
Maximum clearance: 0.04 mm (0.0016 inch)
If the clearance exceeds the maximum, replace the center differential planetary gear.





9. INSPECT CENTER DIFFERENTIAL PLANETARY GEAR BACKLASH
Using a dial indicator, set up the indicator to the tooth edge of the pinion gear (outside) perpendicularly then fix the pinion gear (inside), and inspect while moving the pinon gear (outside).
Standard backlash: 0.01 - 0.04 mm (0.0004 - 0.0016 inch)

HINT:
- Check at more than 3 points on the pinion gear.
- Do the same for the pinion gear.





10. INSPECT CENTER DIFFERENTIAL PLANETARY GEAR THRUST CLEARANCE
Using a feeler gauge, measure the thrust clearance of the pinion gear.
Standard clearance: 0.15 - 0.70 mm (0.0059 - 0.0276 inch)
Maximum clearance: 0.70 mm (0.0276 inch)
If the clearance exceeds the maximum, replace the center differential planetary gear.





11. INSPECT DRIVE SPROCKET RADIAL CLEARANCE
a) Install the center differential planetary gear to the rear output shaft and insert the drive sprocket via the needle roller bearing.
b) Using a dial indicator, measure the radial clearance of the drive sprocket.
Standard clearance: 0.01 - 0.06 mm (0.0004 - 0.0024 inch)
Maximum clearance: 0.06 mm (0.0024 inch)
If the clearance exceeds the maximum, replace the drive sprocket, rear output shaft or needle roller bearing.

REASSEMBLY

HINT: Coat all of the sliding and rotating surfaces with gear oil before reassembly.

1. INSTALL CENTER DIFFERENTIAL PLANETARY GEAR ASSEMBLY





a) Install the center differential planetary ring gear and No.1 center differential planetary gear washer to the center differential planetary gear.

HINT: There is no specific direction for the No.1 center differential planetary gear washer.





b) Using a screwdriver, install the center differential planetary ring gear snap ring.





c) Install the center differential planetary gear assembly to the rear output shaft.





2. INSTALL SYNCHRONIZER INNER RING, SYNCHRONIZER CENTER RING AND SYNCHRONIZER OUTER RING TO CENTER DIFFERENTIAL PLANETARY GEAR ASSEMBLY

NOTICE: Be sure that the synchronizer center ring claw matches the cut-out portion of the planetary gear.

3. ASSEMBLE FRONT DRIVE CLUTCH SLEEVE





a) Install the front drive clutch sleeve to the drive sprocket.

NOTICE: The direction of the front drive clutch sleeve can be distinguished by the difference in the shape of the external surface areas "A" and "B".





b) Install the 3 shifting keys and fix them with the 2 shifting key springs.

NOTICE: Position the key springs so that their end gaps are not aligned.

HINT: There is no specific direction for the shifting key.





4. INSTALL DRIVE SPROCKET AND FRONT DRIVE CLUTCH SLEEVE ASSEMBLY
Install the needle roller bearing, drive sprocket and front drive clutch sleeve assembly, output shaft spacer ball and No.1 spacer.

NOTICE:
- Be sure that the slot of the synchronizer inner ring matches the protrusion of the drive sprocket.
- Align the synchronizer ring slots with the shifting keys.





5. INSTALL OUTPUT SHAFT RADIAL BALL BEARING
Using SST and a press, install a new output shaft radial ball bearing.
SST 09316-60011 (09316-00011, 09316-00071)

NOTICE: Install the output shaft radial ball bearing so that the bearing snap ring groove faces to the rear.





6. INSPECT DRIVE SPROCKET THRUST CLEARANCE





7. ASSEMBLE CLUTCH HUB
Install the high and low clutch sleeve and center differential lock sleeve to the clutch hub.

NOTICE:
- The direction of the clutch hub can be distinguished by size of outer diameters "A" and "B" of the boss.
- The direction of the high and low clutch sleeve can be distinguished by width of the spline.

8. INSTALL CLUTCH HUB ASSEMBLY





a) Install the clutch hub assembly, input gear stopper ball and No. 2 spacer to the rear output shaft.








b) Select a snap ring so that the clearance between the clutch hub and snap ring will be less than 0.15 mm (0.0059 inch).
c) Using a snap ring expander, install a new clutch hub snap ring.
9. INSPECT DRIVE SPROCKET RADIAL CLEARANCE