MANUAL TRANSAXLE UNIT INSPECTION

Click here Click here

PROCEDURE

1. Click here

   INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY

   
   
   1. 

      Using a micrometer, inspect the reverse idler gear shaft.

      Standard outer diameter
      15.97 to 15.98 mm (0.6286 to 0.6292 in.)

      Minimum outer diameter
      15.97 mm (0.6286 in.)

      If the outer diameter is less than the minimum, replace the reverse idler gear shaft.

   2. Using a caliper gauge, inspect the reverse idler gear sub-assembly.

      Standard inside diameter
      16.04 to 16.05 mm (0.6315 to 0.6322 in.)

      Maximum inside diameter
      16.05 mm (0.6322 in.)

      If the inside diameter exceeds the maximum, replace the reverse idler gear sub-assembly.

2. Click here

   INSPECT REVERSE SHIFT FORK

   
   
   1. 

      Using a caliper gauge, inspect the reverse shift fork.

      Standard inside diameter
      A
      14.27 to 14.42 mm (0.5618 to 0.5677 in.)
      B
      14.01 to 14.03 mm (0.5516 to 0.5527 in.)

      Maximum inside diameter
      A
      14.42 mm (0.5677 in.)
      B
      14.03 mm (0.5527 in.)

      If the inside diameter exceeds the maximum, replace the reverse shift fork.

3. Click here

   INSPECT NO. 1 GEAR SHIFT FORK SHAFT

   
   
   1. 

      Using a micrometer, inspect the No. 1 gear shift fork shaft.

      Standard outer diameter
      13.97 to 13.98 mm (0.5499 to 0.5505 in.)

      Minimum outer diameter
      13.97 mm (0.5499 in.)

      If the outer diameter is less than the minimum, replace the No. 1 gear shift fork shaft.

4. Click here

   INSPECT NO. 2 GEAR SHIFT FORK SHAFT

   
   

   1. Using a micrometer, inspect the No. 2 gear shift fork shaft.

      Standard outer diameter
      13.97 to 13.98 mm (0.5499 to 0.5505 in.)

      Minimum outer diameter
      13.97 mm (0.5499 in.)

      If the outer diameter is less than the minimum, replace the No. 2 gear shift fork shaft.

5. Click here

   INSPECT NO. 3 GEAR SHIFT FORK SHAFT

   
   

   1. Using a micrometer, inspect the No. 3 gear shift fork shaft.

      Standard outer diameter
      13.97 to 13.98 mm (0.5499 to 0.5505 in.)

      Minimum outer diameter
      13.97 mm (0.5499 in.)

      If the outer diameter is less than the minimum, replace the No. 3 gear shift fork shaft.

6. Click here

   INSPECT NO. 1 GEAR SHIFT FORK

   
   
   1. 

      Using a vernier caliper, inspect the No. 1 gear shift fork.

      Standard inside diameter and thickness
      A
      9.9 to 10.0 mm (0.3898 to 0.3937 in.)
      B
      9.9 to 10.0 mm (0.3898 to 0.3937 in.)
      C
      14.00 to 14.02 mm (0.5510 to 0.5522 in.)

      If the inside diameter and thickness are outside the specifications, replace the No. 1 gear shift fork.

7. Click here

   INSPECT NO. 2 GEAR SHIFT FORK

   
   
   1. 

      Using a vernier caliper, inspect the No. 2 gear shift fork.

      Standard inside diameter and thickness
      A
      9.9 to 10.0 mm (0.3898 to 0.3937 in.)
      B
      14.00 to 14.02 mm (0.5510 to 0.5522 in.)

      If the inside diameter and thickness are outside the specifications, replace the No. 2 gear shift fork.

8. Click here

   INSPECT NO. 3 GEAR SHIFT FORK

   
   

   1. Using a vernier caliper, inspect the No. 3 gear shift fork.

      Standard inside diameter and thickness
      A
      9.9 to 10.0 mm (0.3898 to 0.3937 in.)
      B
      14.00 to 14.02 mm (0.5510 to 0.5522 in.)

      If the inside diameter and thickness are outside the specifications, replace the No. 3 gear shift fork.

9. Click here

   INSPECT NO. 1 GEAR SHIFT HEAD

   
   
   1. 

      Using a vernier caliper, inspect the No. 1 gear shift head.

      Standard inside diameter
      14.00 to 14.05 mm (0.5510 to 0.5533 in.)

      Maximum inside diameter
      14.05 mm (0.5533 in.)

      If the inside diameter exceeds the maximum, replace the No. 1 gear shift head.

10. Click here

    INSPECT NO. 3 GEAR SHIFT HEAD

    
    
    1. 

       Using a vernier caliper, inspect the No. 3 gear shift head.

       Standard inside diameter
       A
       14.00 to 14.05 mm (0.5510 to 0.5533 in.)
       B
       14.2 to 14.4 mm (0.5591 to 0.5669 in.)

       Maximum inside diameter
       A
       14.05 mm (0.5533 in.)
       B
       14.4 mm (0.5669 in.)

       If the inside diameter exceeds the maximum, replace the No. 3 gear shift head.