Output Shaft Overview, 1st to 4th Gears
Output Shaft Overview, 1st to 4th Gears
• Heat the bearing inner race/tapered roller bearing and synchronizer hub to approximately 100 °C (212 °F) using the inductive heat unit (VAS 6414) or equivalent. Wear protective gloves.
• Adjust the output shaft if it or the tapered roller bearing are being replaced. Refer to => [ Output Shaft Adjusting, 1st to 4th Gears ] Output Shaft Adjusting, 1st to 4th Gears.
• Replace both tapered roller bearings together.
1 Clutch Housing
2 Oil Deflector Ring
3 Dished Washer
• Removing, refer to => [ Removing the dished washer from the output shaft ] Output Shaft, 1st to 4th Gears.
• Installing, refer to => [ Installing the dished washer to the output shaft ] Output Shaft, 1st to 4th Gears.
4 Outer Race/Tapered Roller Bearing
• Removing, refer to => [ Removing the outer race/tapered roller bearing from the clutch housing ] Output Shaft, 1st to 4th Gears.
• Installing, refer to => [ Installing the outer race/tapered roller bearing in the clutch housing ] Output Shaft, 1st to 4th Gears.
5 Bearing Inner Race/Taper Roller Bearing
• Removing, refer to => [ Removing the bearing inner race/tapered roller bearing on the side of the clutch housing ] Output Shaft, 1st to 4th Gears.
• Installing, refer to => [ Installing the bearing inner race/tapered roller bearing on the side of the clutch housing ] Output Shaft, 1st to 4th Gears.
6 Output Shaft
• For 1st through 4th gears.
• Adjusting, refer to => [ Output Shaft Adjusting, 1st to 4th Gears ] Output Shaft Adjusting, 1st to 4th Gears.
7 Needle Bearing
• For 2nd gear.
8 2nd Gear
9 2nd Gear Inner Race
• Replace if there are wear grooves.
• Installed position, refer to => [ Installed position of the outer race, inner race and synchronizer ring, 2nd gear ] Output Shaft, 1st to 4th Gears.
10 2nd Gear Outer Race
• Check the inner friction surface for wear. Refer to => [ Checking the inner contact surface for wear on the 1st gear outer ring, the 2nd gear outer ring, and the 3rd gear outer ring ] Output Shaft, 1st to 4th Gears.
• Check the outer friction surface for wear. Refer to => [ Checking the outer contact surface for wear on the 1st gear outer ring, the 2nd gear outer ring, and the 3rd gear outer ring ] Output Shaft, 1st to 4th Gears.
• Installed position, refer to => [ Installed position of the outer race, inner race and synchronizer ring, 2nd gear ] Output Shaft, 1st to 4th Gears.
11 2nd Gear Synchronizer Ring
• Check the inner running surface for grooves and radial wear.
• Installed position, refer to => [ Installed position of the outer race, inner race and synchronizer ring, 2nd gear ] Output Shaft, 1st to 4th Gears.
12 Locking Collar with Synchronizer Hub for 1st and 2nd Gears
• After removing the lock ring - item 13 -, remove the 2nd gear. Refer to => [ Removing the locking collar and the synchronizer hub for 1st and 2nd gears ] Output Shaft, 1st to 4th Gears.
• Disassembling, refer to => [ Disassembling and assembling the locking collar and the synchronizer hub for 1st, 2nd, 3rd and 4th gears ] Output Shaft, 1st to 4th Gears.
• Assembling the locking collar/synchronizer hub, refer to => [ Disassembling and assembling the locking collar and the synchronizer hub for 1st, 2nd, 3rd and 4th gears ] Output Shaft, 1st to 4th Gears and to => [ Assembly: locking collar/synchronizer hub for 1st, 2nd, 3rd and 4th gears ] Output Shaft, 1st to 4th Gears.
• Installed position, refer to => [ Installed position: locking collar/synchronizer hub for 1st and 2nd gears ] Output Shaft, 1st to 4th Gears.
• Installing, refer to => [ Heating and installing the locking collar/synchronizer hub for 1st and 2nd gears ] Output Shaft, 1st to 4th Gears.
13 Lock Ring
14 1st Gear Synchronizer Ring
• Check the inner running surface for grooves and radial wear.
• Installed position, refer to => [ Installing the synchronizer ring for the 1st gear outer race and inner race ] Output Shaft, 1st to 4th Gears.
15 1st Gear Outer Race
• Check the inner friction surface for wear. Refer to => [ Checking the inner contact surface for wear on the 1st gear outer ring, the 2nd gear outer ring, and the 3rd gear outer ring ] Output Shaft, 1st to 4th Gears.
• Check the outer friction surface for wear. Refer to => [ Checking the outer contact surface for wear on the 1st gear outer ring, the 2nd gear outer ring, and the 3rd gear outer ring ] Output Shaft, 1st to 4th Gears.
• Installed position, refer to => [ Installing the synchronizer ring for the 1st gear outer race and inner race ] Output Shaft, 1st to 4th Gears.
16 1st Gear Inner Race
• Replace if there are wear grooves.
• Installed position, refer to => [ Installing the synchronizer ring for the 1st gear outer race and inner race ] Output Shaft, 1st to 4th Gears.
17 Needle Bearing
• For 1st gear.
18 1st Gear
• Install on the output shaft. Refer to => [ Install the 1st gear with needle roller bearing ] Output Shaft, 1st to 4th Gears.
19 Thrust Washer
• For 1st and 4th gears.
• Quantity: 2
• The tab on the thrust washer must fit into the hole in the output shaft.
20 Washer
• Holds the thrust washers - item 19 - in place on the output shaft.
21 Needle Bearing
• For 4th gear.
22 4th Gear
23 4th Gear Synchronizer Ring
• Made of either brass or steel.
• Checking for wear, refer to => [ Checking the 4th gear synchronizer ring for wear ] Output Shaft, 1st to 4th Gears.
24 Locking Collar with Synchronizer Hub for 3rd and 4th Gears
• After removing the lock ring - item 25 -, remove the 4th gear. Refer to => [ Removing the 3rd and 4th gear synchronizer hub/locking collar with the 4th gear ] Output Shaft, 1st to 4th Gears.
• Disassembling, refer to => [ Disassembling and assembling the locking collar and the synchronizer hub for 1st, 2nd, 3rd and 4th gears ] Output Shaft, 1st to 4th Gears.
• Assembling the locking collar/synchronizer hub, refer to => [ Disassembling and assembling the locking collar and the synchronizer hub for 1st, 2nd, 3rd and 4th gears ] Output Shaft, 1st to 4th Gears and to => [ Assembly: locking collar/synchronizer hub for 1st, 2nd, 3rd and 4th gears ] Output Shaft, 1st to 4th Gears.
• Installed position: locking collar/synchronizer hub, refer to => [ Installed position: locking collar/synchronizer hub for 3rd and 4th gears ] Output Shaft, 1st to 4th Gears.
• Installing, refer to => [ Heating and installing the synchronizer hub with locking collar for 3rd and 4th gears ] Output Shaft, 1st to 4th Gears.
25 Lock Ring
26 3rd Gear Synchronizer Ring
• Check the inner running surface for grooves and radial wear.
• Installed position, refer to => [ Installing the outer ring synchronizer ring and 3rd gear inner ring ] Output Shaft, 1st to 4th Gears.
27 3rd Gear Outer Race
• Check the inner friction surface for wear. Refer to => [ Checking the inner contact surface for wear on the 1st gear outer ring, the 2nd gear outer ring, and the 3rd gear outer ring ] Output Shaft, 1st to 4th Gears.
• Check the outer friction surface for wear. Refer to => [ Checking the outer contact surface for wear on the 1st gear outer ring, the 2nd gear outer ring, and the 3rd gear outer ring ] Output Shaft, 1st to 4th Gears.
• Installed position, refer to => [ Installing the outer ring synchronizer ring and 3rd gear inner ring ] Output Shaft, 1st to 4th Gears.
28 3rd Gear Inner Race
• Replace if there are wear grooves.
• Installed position, refer to => [ Installing the outer ring synchronizer ring and 3rd gear inner ring ] Output Shaft, 1st to 4th Gears.
29 Needle Bearing
• For 3rd gear.
30 3rd Gear
• Install on the output shaft, refer to => [ Install the 3rd gear selector gear with needle bearing ] Output Shaft, 1st to 4th Gears.
31 Bearing Inner Race/Taper Roller Bearing
• Removing, refer to => [ Remove the bearing inner race/tapered roller bearing on the side of the transmission housing ] Output Shaft, 1st to 4th Gears.
• Installing, refer to => [ Installing the bearing inner race/tapered roller bearing on the side of the transmission housing ] Output Shaft, 1st to 4th Gears.
32 Lock Ring
• Select the correct one when replacing the tapered roller bearing - item 31 - and the output shaft - item 6 -. Refer to => [ Selecting the lock ring ] Output Shaft, 1st to 4th Gears.
33 Outer Race/Tapered Roller Bearing
• Removing, refer to => [ Removing the outer race/tapered roller bearing from the transmission housing ] Output Shaft, 1st to 4th Gears.
• Installing, refer to => [ Installing the outer race/tapered roller bearing into the transmission housing ] Output Shaft, 1st to 4th Gears.
34 Adjusting Shim
• Selecting the correct shim thickness, refer to => [ Output Shaft Adjusting, 1st to 4th Gears ] Output Shaft Adjusting, 1st to 4th Gears.
35 Transmission Housing