Disassembly

R155F MANUAL TRANSMISSION: OUTPUT SHAFT:

DISASSEMBLY





1. INSPECT 1ST GEAR THRUST CLEARANCE
(a) Using a dial indicator measure the thrust clearance of the 1st gear.
Standard clearance:
0.20 to 0.45 mm(0.0079 to 0.0177 in.)





2. INSPECT 2ND GEAR THRUST CLEARANCE
(a) Using a dial indicator measure the thrust clearance of the 2nd gear.
Standard clearance:
0.10 to 0.25 mm (0.0039 to 0.0098 in.)





3. INSPECT 3RD GEAR THRUST CLEARANCE
(a) Using a feeler gauge, measure the thrust clearance of the 3rd gear.
Standard clearance:
0.10 to 0.25 mm (0.0039 to 0.0098 in.)





4. INSPECT 1ST GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the radial clearance of the 1st gear.
Standard clearance:
0.020 to 0.073 mm (0.0008 to 0.0029 in.)
If the clearance is not within the specified values, replace the 1st gear needle roller bearing with a new one.





5. INSPECT 2ND GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the radial clearance of the 2nd gear.
Standard clearance:
0.015 to 0.068mm (0.0006 to 0.0027 in.)
If the clearance is not within the specified values, replace the 2nd gear needle roller bearing with a new one.





6. INSPECT 3RD GEAR RADIAL CLEARANCE
(a) Using a dial indicator, measure the radial clearance of the 3rd gear.
Standard clearance:
0.015 to 0.068 mm (0.0006 to 0.0027 in.)
If the clearance is not within the specified values, replace the 3rd gear needle roller bearing with a new one.





7. REMOVE 1ST GEAR
(a) Using SST and a press, remove the 5th gear, output shaft center bearing, 1st gear thrust washer and 1st gear from the output shaft.
SST: 09950-00020





8. REMOVE NO. 1 SYNCHRONIZER RING
(a) Remove synchronizer ring No. 1 (for the 1st gear) from the output shaft.





9. REMOVE 1ST GEAR THRUST WASHER PIN OR BALL
(a) Remove the 1st gear thrust washer pin from the output shaft.





10. REMOVE 1ST GEAR NEEDLE ROLLER BEARING
(a) Remove the 1st gear needle roller bearing from the output shaft.





11. REMOVE 1ST GEAR BEARING SPACER
(a) Remove the 1st gear bearing spacer from the output shaft.





12. REMOVE BEARING SHAFT SNAP RING
(a) Using 2 screwdrivers and a hammer, remove the bearing shaft snap ring from the output shaft.

NOTE: Use a shop rag to prevent the snap ring from flying off.





13. REMOVE 2ND GEAR
(a) Using SST and a press, remove the transmission clutch hub No. 1, reverse gear, synchronizer ring No. 1 and 2nd gear from the output shaft.
SST: 09950-00020





14. REMOVE 2ND GEAR NEEDLE ROLLER BEARING
(a) Remove the 2nd gear needle roller bearing from the output shaft.





15. REMOVE REVERSE GEAR
(a) Remove the reverse gear, 3 synchromesh shifting keys No. 1 and 3 synchromesh shifting key springs.
Use a shop rag to prevent the shifting key and the shifting spring from popping out.





16. REMOVE CLUTCH HUB SET SHAFT SNAP RING
(a) Using snap ring pliers, remove the clutch hub set shaft snap ring from the output shaft.

NOTE: Do not damage the sliding surface of the bearing.





17. REMOVE 3RD GEAR
(a) Using SST and a press, remove the clutch hub No. 2 with the hub sleeve No. 2, synchronizer ring No. 2 and 3rd gear from the output shaft.
SST: 09950-00020





18. REMOVE 3RD GEAR NEEDLE ROLLER BEARING
(a) Remove the 3rd gear needle roller bearing from the output shaft.





19. REMOVE NO. 2 TRANSMISSION HUB SLEEVE
(a) Remove the transmission hub sleeve No. 2, 3 synchromesh shifting key springs and 3 synchromesh shifting keys No. 2 from the transmission clutch hub No. 2.