Output Shaft Assemble Solstice
Tools Required
Important: Lubricate all bearings with transmission fluid during assembly.
- Install the 3rd gear bearing (130) and the 3rd gear (133) on the front of the output shaft.
- Remove the sleeve from the 3rd/4th synchronizer assembly.
- Position the synchronizer hub and 3rd gear blocking rings on the output shaft. The smooth side of the hub goes forward, the 4th gear side.
- Using a hydraulic press, install a NEW 3rd/4th synchronizer hub on the output shaft.
• | Support the synchronizer hub on the center flange with a suitable tube. |
• | Align the blocking rings with the hub and the 3rd gear while pressing. |
- Using
J 8001-3
or
J 26900-12
(1) and
J 26900-13
(2), measure the 3rd gear axial play.
Specification
• | Standard Clearance: 0.10-0.25 mm (0.0039-0.00098 in) |
• | Maximum Clearance: 0.30 mm (0.0118 in) |
5.3. | Lift up on the gear to measure the clearance. |
- If the clearance exceeds the maximum, ensure the hub is installed completely.
- If the clearance exceeds the maximum, inspect the 3rd gear, the output shaft, or the 3rd/4th synchronizer hub for wear.
- If clearance is lower than the standard clearance, inspect the 3rd gear, the output shaft, or the 3rd/4th synchronizer hub for burrs.
- Repair or replace the damaged or worn component.
- Install the 3rd/4th synchronizer sleeve on the hub while pushing in on the inserts.
The step shoulder side of the sleeve goes forward to 4th gear.
Important: The retaining ring is a select fit. Always install a new retaining ring.
- Select the maximum thickness retaining ring for the 3rd/4th synchronizer hub, that will fit in the groove. Refer to
3rd and 4th Gear Synchronizer Retaining Ring Specifications
.
- Install the 3rd/4th synchronizer hub retaining ring.
- Install the 2nd gear bearing (123) and the 2nd
gear (120) on the rear of the output shaft.
- Remove the 1st gear blocking rings from the 1st/2nd synchronizer assembly. The rings will be installed after pressing on the hub.
- Install the 1st/2nd synchronizer hub assembly (215) on the output shaft, with the shift fork side of the reverse gear toward 2nd gear.
- Using a hydraulic press, press the 1st/2nd synchronizer
assembly onto the output shaft.
• | Support the synchronizer hub on the center flange. |
• | Align the tabs of the blocking rings to the notches in the synchronizer hub and the 2nd speed gear. |
- Using
J 8001-3
or
J 26900-12
(1) and
J 26900-13
(2), measure the 2nd gear axial play.
Specification
• | Standard Clearance: 0.10-0.25 mm (0.0039-0.00098 in) |
• | Maximum Clearance: 0.30 mm (0.0118 in) |
17.3. | Lift up on the gear to measure the clearance. |
- If the clearance exceeds the maximum, ensure the hub is installed completely.
- If the clearance exceeds the maximum, inspect the 2nd gear, the output shaft or the 1st/2nd synchronizer hub for wear.
- If clearance is lower than the standard clearance, inspect the 2nd gear, the output shaft or the 2nd/3rd synchronizer hub for burrs.
- Repair or replace the damaged or worn component.
Important: The retaining ring is a select fit. Always install a new retaining ring.
- Select the maximum thickness retaining ring for the 1st/2nd synchronizer hub, that will fit in the groove. Refer to
1st and 2nd Gear Synchronizer Retaining Ring Specifications
.
- Install the 1st/2nd synchronizer hub retaining ring.
- Install the 1st gear synchronizer rings. Align the blocking ring tabs to the notches
in the hub.
- Install the 1st gear spacer.
- Install the 1st gear thrust washer lock pin.
- Install the following components to the rear of the output shaft:
• | The 1st gear bearing (113) |
• | The 1st gear thrust washer (116) |
• | The output shaft rear bearing (193) |
• | The shorter shoulder faces toward the bearing. |
- Using a hydraulic press and
J 44340
, press the output
rear bearing and the 5th gear onto the output shaft.
• | Ensure the tabs of the blocking rings align to the notches in the synchronizer hub. |
• | The retaining ring groove side of the bearing faces 5th gear. |
- Using
J 8001-3
or
J 26900-12
(1) and
J 26900-13
(2), measure the 1st gear axial play.
Specification
• | Standard Clearance: 0.20-0.45 mm (0.0079-0.0177 in) |
• | Maximum Clearance: 0.50 mm (0.0197 in) |
29.3. | Lift up on the gear to measure the clearance. |
- If the clearance exceeds the maximum, ensure the rear output shaft bearing is installed completely.
- If the clearance exceeds the maximum, inspect the 1st gear, the output shaft or the thrust washer for wear.
- If clearance is lower than the standard clearance, inspect the 1st gear, the output shaft or the thrust washer for burrs.
- Repair or replace the damaged or worn component.
Important: The retaining ring is a select fit. Always install a new retaining ring.
- Select the maximum thickness retaining ring for the 5th gear, that will fit in the groove. Refer to
Fifth Gear Retaining Ring Specifications
.
- Install the 5th gear retaining ring.
- Install the reluctor wheel spacer.
- Install the speed sensor reluctor wheel locating ball.
- Install the speed sensor reluctor wheel.
- Install the speed sensor reluctor wheel rear spacer.
- Install the rear output shaft bearing.