INPUT SHAFT INSPECTION

PROCEDURE


  1. INSPECT 3RD GEAR THRUST CLEARANCE


    1. A01VKCU

      Using a feeler gauge, measure the 3rd gear thrust clearance.

      Standard clearance
      0.10 to 0.35 mm (0.0039 to 0.0138 in.)
      Maximum clearance
      0.35 mm (0.0138 in.)

      If the clearance is more than the maximum, replace the No. 2 transmission clutch hub, 3rd gear or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  2. INSPECT 5TH GEAR THRUST CLEARANCE


    1. A01VIZD

      Using a dial indicator, measure the 5th gear thrust clearance.

      Standard clearance
      0.10 to 0.50 mm (0.0039 to 0.0198 in.)
      Maximum clearance
      0.50 mm (0.0196 in.)

      If the clearance is more than the maximum, replace the No. 3 transmission clutch hub, 5th gear or 5th thrust washer. Replace the part or parts determined to be the most likely cause of the problem.

  3. INSPECT 3RD GEAR RADIAL CLEARANCE


    1. A01VFW1

      Using a dial indicator, measure the 3rd gear radial clearance.

      Standard clearance
      0.015 to 0.058 mm (0.0006 to 0.0023 in.)
      Maximum clearance
      0.058 mm (0.0023 in.)

      If the clearance is more than the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  4. INSPECT 4TH GEAR RADIAL CLEARANCE


    1. A01VGCU

      Using a dial indicator, measure the 4th gear radial clearance.

      Standard clearance
      0.015 to 0.058 mm (0.0006 to 0.0023 in.)
      Maximum clearance
      0.058 mm (0.0023 in.)

      If the clearance is more than the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  5. INSPECT 5TH GEAR RADIAL CLEARANCE


    1. A01VJGH

      Using a dial indicator, measure the 5th gear radial clearance.

      Standard clearance
      0.015 to 0.058 mm (0.0006 to 0.0023 in.)
      Maximum clearance
      0.058 mm (0.0023 in.)

      If the clearance is more than the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  6. INSPECT 4TH GEAR THRUST CLEARANCE


    1. A01VHIS

      Using a dial indicator, measure the 4th gear thrust clearance.

      Standard clearance
      0.10 to 0.55 mm (0.0039 to 0.0217 in.)
      Maximum clearance
      0.55 mm (0.0217 in.)

      If the clearance is more than the maximum, replace the No. 2 transmission clutch hub, 4th gear or 5th thrust washer. Replace the part or parts determined to be the most likely cause of the problem.

  7. INSPECT INPUT SHAFT


    1. Check the input shaft for wear and damage.

    2. A01VE6N

      Using a dial indicator, check the input shaft runout.

      Maximum runout
      0.03 mm (0.0012 in.)

      If the runout exceeds the maximum, replace the input shaft.

    3. A01VH3JE02

      Using a micrometer, measure the outer diameter of the input shaft journal surface, at the locations indicated.

      Standard outer diameter
      Part A
      25.502 to 25.515 mm (1.0040 to 1.0045 in.)
      Part B
      30.985 to 31.000 mm (1.2199 to 1.2205 in.)
      Part C and D
      33.985 to 34.000 mm (1.3380 to 1.3386 in.)
      Part E
      23.002 to 23.015 mm (0.9056 to 0.9056 in.)
      Part F
      22.967 to 23.000 mm (0.9042 to 0.9055 in.)

      If the outer diameter is less than the minimum, replace the input shaft.

      If the outer diameters are below the minimums, replace the input shaft.

  8. INSPECT 3RD GEAR


    1. A01VH2I

      Using a cylinder gauge, measure the inside diameter of the 3rd gear.

      Standard inside diameter
      39.015 to 39.031 mm (1.5360 to 1.5367 in.)
      Maximum inside diameter
      39.031 mm (1.5367 in.)

      If the inside diameter is more than the maximum, replace the 3rd gear.

  9. INSPECT 4TH GEAR


    1. A01VH2I

      Using a cylinder gauge, measure the inside diameter of the 4th gear.

      Standard inside diameter
      39.015 to 39.031 mm (1.5360 to 1.5367 in.)
      Maximum inside diameter
      39.031 mm (1.5367 in.)

      If the inside diameter is more than the maximum, replace the 4th gear.

  10. INSPECT 5TH GEAR


    1. A01VH2I

      Using a cylinder gauge, measure the inside diameter of the 5th gear.

      Standard inside diameter
      36.015 to 36.031 mm (1.4180 to 1.4185 in.)
      Maximum inside diameter
      36.031 mm (1.4185 in.)

      If the inside diameter is more than the maximum, replace the 5th gear.

  11. INSPECT 3RD GEAR SYNCHRONIZER RING


    1. Check for wear and damage.

    2. Coat the 3rd gear cone with gear oil.

    3. A01VEL7

      Turn the 3rd gear synchronizer ring in both directions while pushing it against the 3rd gear cone and check that it locks in both directions. If the 3rd gear synchronizer ring does not lock, replace the 3rd gear synchronizer ring.

    4. A01VFDN

      Using a feeler gauge, measure the clearance between the 3rd gear synchronizer ring back and the 3rd gear spline end.

      Standard clearance
      0.75 to 1.65 mm (0.030 to 0.064 in.)
      Minimum clearance
      0.75 mm (0.031 in.)

      If the clearance is less than the minimum, replace the 3rd gear synchronizer ring.

  12. INSPECT 4TH GEAR SYNCHRONIZER RING


    1. Check for wear and damage.

    2. Coat the 4th gear cone with gear oil.

    3. A01VEL7

      Turn the 4th gear synchronizer ring in both directions while pushing it against the 4th gear cone and check that it locks in both directions. If the 4th gear synchronizer ring does not lock, replace the 4th gear synchronizer ring.

    4. A01VFDN

      Using a feeler gauge, measure the clearance between the 4th gear synchronizer ring back and the 4th gear spline end.

      Standard clearance
      0.75 to 1.65 mm (0.030 to 0.064 in.)
      Minimum clearance
      0.75 mm (0.030 in.)

      If the clearance is less than the minimum, replace the 4th gear synchronizer ring.

  13. INSPECT 5TH GEAR SYNCHRONIZER RING


    1. Check for wear and damage.

    2. Coat the 5th gear cone with gear oil.

    3. A01VEL7

      Turn the 5th gear synchronizer ring in both directions while pushing it against the 5th gear cone and check that it locks in both directions. If the 5th gear synchronizer ring does not lock, replace the 5th gear synchronizer ring.

    4. A01VFDN

      Using a feeler gauge, measure the clearance between the 5th synchronizer ring back and the 5th gear spline end.

      Standard clearance
      0.80 to 1.60 mm (0.031 to 0.063 in.)
      Minimum clearance
      0.80 mm (0.031 in.)

      If the clearance is less than the minimum, replace the 5th gear synchronizer ring.

  14. INSPECT NO. 2 TRANSMISSION HUB SLEEVE


    1. A01VEJDE03

      Using a vernier caliper, measure the width of the No. 2 transmission hub sleeve groove (A) and the thickness of the claw part on the No. 2 gear shift fork (B), and then calculate the clearance.

      Standard clearance (A-B)
      0.15 to 0.35 mm (0.0059 to 0.0138 in.)

      If the clearance is not as specified, replace the No. 2 transmission hub sleeve and No. 2 gear shift fork.

  15. INSPECT NO. 3 TRANSMISSION HUB SLEEVE


    1. A01VIAJE03

      Using a vernier caliper, measure the width of the No. 3 transmission hub sleeve groove (A) and the thickness of the claw part on the No. 3 gear shift fork (B), and then calculate the clearance.

      Standard clearance (A-B)
      0.15 to 0.35 mm (0.0059 to 0.0138 in.)

      If the clearance is not as specified, replace the No. 3 transmission hub sleeve and No. 3 gear shift fork.