OUTPUT SHAFT INSPECTION


  1. INSPECT 1ST GEAR THRUST CLEARANCE


    1. A0137ZKE01

      Using a feeler gauge, measure the 1st gear thrust clearance.

      Standard clearance
      0.10 to 0.35 mm (0.00394 to 0.0137 in.)
      Maximum clearance
      0.35 mm (0.0137 in.)

      If the clearance is more than the maximum, replace the No. 1 transmission clutch hub, 1st gear or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  2. INSPECT 2ND GEAR THRUST CLEARANCE


    1. A0138I1E01

      Using a feeler gauge, measure the 2nd gear thrust clearance.

      Standard clearance
      0.10 to 0.55 mm (0.00394 to 0.0216 in.)
      Maximum clearance
      0.55 mm (0.0216 in.)

      If the clearance is more than the maximum, replace the 2nd gear, No. 1 transmission clutch hub, 3rd driven gear or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  3. INSPECT 1ST GEAR RADIAL CLEARANCE


    1. A0138AJE01

      Using a dial indicator, measure the 1st gear radial clearance.

      Standard clearance
      0.015 to 0.056 mm (0.000591 to 0.00220 in.)
      Maximum clearance
      0.056 mm (0.00220 in.)

      If the clearance is more than the maximum, replace the 1st gear needle roller bearing, 1st gear or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  4. INSPECT 2ND GEAR RADIAL CLEARANCE


    1. A0138TQE01

      Using a dial indicator, measure the 2nd gear radial clearance.

      Standard clearance
      0.015 to 0.056 mm (0.000591 to 0.00220 in.)
      Maximum clearance
      0.056 mm (0.00220 in.)

      If the clearance is more than the maximum, replace the 2nd gear needle roller bearing, 2nd gear or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  5. INSPECT OUTPUT SHAFT


    1. A0137RUE01

      Using a dial indicator, measure the output shaft runout.

      Maximum runout
      0.03 mm (0.00118 in.)

      If the runout is more than the maximum, replace the output shaft.

    2. A0138ZRE03

      Using a micrometer, measure the outer diameter of the output shaft journals at the locations indicated in the illustration.

      Standard outer diameter
      Part A
      23.002 to 23.015 mm (0.9056 to 0.9061 in.)
      Part B and C
      28.3 mm (1.11 in.)
      Part D and E
      33.985 to 34.000 mm (1.3380 to 1.3385 in.)
      Part F
      25.002 to 25.015 mm (0.9844 to 0.9848 in.)

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

  6. INSPECT 1ST GEAR


    1. A01366SE01

      Using a cylinder gauge, measure the inside diameter of the 1st gear.

      Standard inside diameter
      39.015 to 39.031 mm (1.5361 to 1.5366 in.)
      Maximum inside diameter
      39.031 mm (1.5366 in.)

      If the inside diameter is more than the maximum, replace the 1st gear.

  7. INSPECT 2ND GEAR


    1. A0136P2E01

      Using a cylinder gauge, measure the inside diameter of the 2nd gear.

      Standard inside diameter
      39.015 to 39.031 mm (1.5361 to 1.5366 in.)
      Maximum inside diameter
      39.031 mm (1.5366 in.)

      If the inside diameter is more than the maximum, replace the 2nd gear.

  8. INSPECT 1ST GEAR SYNCHRONIZER RING


    1. A0137Y8E01

      Check for wear and damage.

    2. Coat the 1st gear cone with gear oil.

    3. Turn the 1st gear synchronizer ring in both directions while pushing it against the 1st gear cone and check that it locks in both directions.

      If the 1st gear synchronizer ring does not lock, replace the 1st gear synchronizer ring.

    4. A0136VHE01

      Using a feeler gauge, measure the clearance between the 1st gear synchronizer ring and the 1st gear spline end.

      Standard clearance
      0.75 to 1.65 mm (0.0296 to 0.0649 in.)
      Minimum clearance
      0.75 mm (0.0296 in.)

      If the clearance is less than the minimum, replace the 1st gear synchronizer ring.

  9. INSPECT 2ND GEAR SYNCHRONIZER RING


    1. A0138YZE01

      Check for wear and damage.

    2. Coat the 2nd gear cone with gear oil.

    3. Turn the 2nd gear synchronizer ring in both directions while pushing it against the 2nd gear cone and check that it locks in both directions.

      If the 2nd gear synchronizer ring does not lock, replace the 2nd gear synchronizer ring.

    4. A0135Z4E01

      Using a feeler gauge, measure the clearance between the 2nd gear synchronizer ring and the 2nd gear spline end.

      Standard clearance
      0.75 to 1.65 mm (0.0296 to 0.0649 in.)
      Minimum clearance
      0.75 mm (0.0296 in.)

      If the clearance is less than the minimum, replace the 2nd gear synchronizer ring.

  10. INSPECT REVERSE GEAR


    1. A0138KCE01

      Using a vernier caliper, measure the width of the reverse gear groove (A) and the thickness of the claw part on the No. 1 gear shift fork (B), and then calculate the clearance.

      Standard clearance (A - B)
      0.15 to 0.35 mm (0.00591 to 0.0137 in.)

      If the clearance is not as specified, replace the No. 1 gear shift fork and the reverse gear.