MANUAL TRANSMISSION UNIT INSPECTION


  1. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE


    1. A01KEBX

      Using a feeler gauge, check the counter shaft 5th gear thrust clearance.

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

  2. INSPECT COUNTER SHAFT 5TH GEAR RADIAL CLEARANCE


    1. A01KFUJ

      Using a dial indicator, check the radial clearance of the counter shaft 5th gear.

      Standard clearance
      0.015 to 0.068 mm (0.00059 to 0.0027 in.)

      If the value is not within the specification, replace the counter shaft 5th gear bearing with a new one.

  3. INSPECT SYNCHRONIZER RING NO.3


    1. A01KHD1

      Apply the gear oil to the cone part of the gear spline piece No. 5, and check that it does not rotate to the circumference direction while the synchronizer ring No. 3 is pushed.

    2. A01KGKO

      Check the clearance between the synchronizer ring No. 3 and the gear spline piece No. 5 while the synchronizer ring No. 3 pushed to the cone part of the gear spline piece No. 5.

      Standard clearance
      0.85 to 1.55 mm (0.0334 to 0.0610 in.)

      If the clearance is out of the specification, replace the synchronizer ring No. 3 with a new one.

  4. INSPECT TRANSMISSION HUB SLEEVE NO.3


    1. A01KG6L

      Check the sliding condition between the counter shaft 5th gear and the transmission hub sleeve No. 3.

    2. Check the tip of the spline gear of the transmission hub sleeve No. 3 for wear.

    3. A01KF2M

      Using a vernier caliper, check the transmission hub sleeve No. 3 groove and the thickness of the claw part of the gear shift fork No. 3 to calculate the clearance.

      Standard clearance
      0.26 to 0.84 mm (0.0102 to 0.0331 in.)

      If the clearance is out of the specification, replace the transmission hub sleeve No. 3 and the gear shift fork No. 3 with new ones.

  5. INSPECT COUNTER SHAFT 5TH GEAR


    1. A01KICH

      Using a cylinder gauge, check the inner diameter of the counter shaft 5th gear.

      Standard clearance
      38.015 to 38.040 mm (1.4967 to 1.4976 in.)
      Maximum clearance
      38.040 mm (1.4976 in.)

      If the value exceeds the specification, replace the counter shaft 5th gear with a new one.

  6. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A01KF1X

      Using a caliper gauge, check the inner diameter of the reverse gear.

      Standard clearance
      24.040 to 24.061 mm (0.9465 to 0.9473 in.)
      Maximum clearance
      24.061 mm (0.9473 in.)

      If the value exceeds the specification, replace the reverse idler gear with a new one.

    2. Using a micrometer, check the outer diameter of the sliding part of the reverse idler gear on the reverse idler gear shaft.

      Standard clearance
      23.979 to 24.000 mm (0.9441 to 0.9449 in.)
      Minimum clearance
      23.979 mm (0.9441 in.)
    3. A01KGVE

      Using a feeler gauge, check the thrust clearance of the shoe part between the reverse idler gear and the reverse shift arm.

      Standard clearance
      0.05 to 0.35 mm (0.0020 to 0.0138 in.)

  7. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE


    1. A01KH5C

      Install the reverse idler gear on the reverse idler gear shaft, and fix to the vice.

    2. Using a dial indicator, check the radial clearance of the reverse idler gear.

      Standard clearance
      0.040 to 0.082 mm (0.0016 to 0.0032 in.)