Output Shaft - Assembly

note
The numbers in brackets in the following text refer to the exploded view on Exploded View - Output Shaft.Lubricate each gear and bush with clean engine oil during assembly.Examine all gears, bearings and sleeves for damage, chipped teeth and wear beyond the service limits. Replace all suspect components and always use new circlips, a new output shaft seal and a new sprocket tab washer to assemble the shaft.
warning
When using a press, always wear overalls, eye, face and hand protection. Objects such as bearings frequently break-up under load and the debris caused during break-up may cause damage and injury to unprotected parts of the body.Never wear loose clothing, which could become trapped in the press and cause crushing injuries to the hand, arms or other parts of the anatomy.
caution
Bushes and gears with oil holes must always be MISALIGNED with the corresponding oil holes in the output shaft. Reduced oil pressure and gear lubrication may result from alignment of the oil holes, which would cause premature wear of engine and transmission components.
caution
Removing the output shaft bearing from the shaft will damage the bearing and snap ring. Never reuse removed bearings or snap rings as use of damaged or weakened components could lead to engine and transmission damage.
caution
Press only on the bearing inner race to prevent bearing damage.
  1. Working from the output sprocket end of the shaft, fit a new bearing (24) and a new sprocket spacer (25) to the shaft using a press and press bars. Fit the sleeve with the large chamfer facing outwards.
    2. Bearing to output shaft ccbo_2

    1. Output shaft

    2. Bearing

    3. Press bars

  2. Lubricate and fit a new output shaft seal (26).
  3. Transfer the shaft to the vice and secure between soft jaws. Fit the output sprocket (27), new tab washer (28) and nut (29). Tighten the nut to 85 Nm. Close the tab washer.
  4. Withdraw the shaft from the vice and continue to assemble from the opposite end to the output sprocket.
  5. Fit the plain bush (20) to the shaft.
  6. Locate second gear (21) to the shaft as noted during disassembly, with the large step side facing towards the output sprocket end. Fit the splined thrust washer (19) and retain with a new circlip (18) as shown below.
    7. 2nd gear circlip cdmr

    1. Second gear

    2. Thrust washer

    3. Circlip

  7. Fit sixth gear (17) as noted during disassembly, with the selector fork groove facing away from the output sprocket end. Ensure that the oil holes in the gear DO NOT align with the corresponding oil hole in the output shaft.
  8. Fit a new circlip (16) to retain sixth gear. Fit the splined thrust washer (15) to the rear of third gear as shown below.
    9. 6th gear circlip cdms

    1. Third gear

    2. Splined thrust washer

    3. Circlip

  9. Fit the splined bush (13) for third gear. Ensure that the oil holes in the gear DO NOT align with the corresponding oil hole in the output shaft. Fit third gear (14) to the shaft with the large step side facing away from the output sprocket.
  10. Fit the splined lock washers (12 and 11), ensuring the tabs in the smaller washer (11) locate in the slots in the larger washer (12) as shown below.
    11. 3rd gear circlip cdmt

    1. Third gear

    2. Large splined lock washer

    3. Small splined lock washer

  11. Fit the splined bush (10) from fourth gear. Ensure that the oil holes in the gear DO NOT align with the corresponding oil hole in the output shaft.
  12. Fit fourth gear (9) as noted during disassembly, with the larger step side facing towards the output sprocket.
  13. Fit the splined thrust washer (8) and retain with a new circlip (7) as shown below.
    14. 4th gear circlip cdmu

    1. Fourth gear

    2. Splined thrust washer

    3. Circlip

  14. Fit the fifth gear (6) to the shaft with the groove facing towards the output sprocket. Ensure that the oil holes in the gear DO NOT align with the corresponding oil hole in the output shaft.
  15. Fit the first gear thrust washer (5) and plain bush (4).
    16. note
    When fitting first gear, ensure the solid side of the gear faces the clutch.
  16. Fit first gear (3) to the shaft as marked during disassembly as shown below.
    17. 1st gear cdmv_1

    1. First gear

    2. Thrust washer

    3. Thrust washer

    4. Needle roller bearing

  17. Finally fit the thrust washer (2) and needle roller bearing (1) to the end of the shaft.