INPUT SHAFT INSPECTION


  1. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY

    A0136MT

    1. Using a micrometer, inspect the reverse idler gear shaft.

      Standard outer diameter
      15.97 to 15.98 mm (0.6287 to 0.6291 in.)
      Minimum outer diameter
      15.97 mm (0.6287 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.

      Standard internal diameter
      16.04 to 16.05 mm (0.6315 to 0.6319 in.)
      Maximum internal diameter
      16.05 mm (0.6319 in.)

      If the internal diameter exceeds the maximum, replace the reverse idler gear.

  2. INSPECT REVERSE SHIFT FORK

    A013888E01

    1. Using a caliper gauge, inspect the reverse shift fork.

      Standard internal diameter
      A
      14.27 to 14.42 mm (0.5591 to 0.5677 in.)
      B
      14.01 to 14.03 mm (0.5516 to 0.5524 in.)
      Maximum internal diameter
      A
      14.42 mm (0.5677 in.)
      B
      14.03 mm (0.5524 in.)

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

  3. INSPECT GEAR SHIFT FORK SHAFT NO. 1

    A0136Y0

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

      Standard outer diameter
      13.97 to 13.98 mm (0.5500 to 0.5504 in.)
      Minimum outer diameter
      13.97 mm (0.5500 in.)

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

  4. INSPECT GEAR SHIFT FORK SHAFT NO. 2

    A0136BE

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

      Standard outer diameter
      13.97 to 13.98 mm (0.5500 to 0.5504 in.)
      Minimum outer diameter
      13.97 mm (0.5500 in.)

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

  5. INSPECT GEAR SHIFT FORK SHAFT NO. 3

    A0137O4

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

      Standard outer diameter
      13.97 to 13.98 mm (0.5500 to 0.5504 in.)
      Minimum outer diameter
      13.97 mm (0.5500 in.)

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

  6. INSPECT GEAR SHIFT FORK NO. 1

    A01387ZE01

    1. Using vernier calipers, inspect gear shift fork No. 1.

      Standard internal 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 (0.5512 to 0.5520 in.)

      If the clearance is outside the specifications, replace gear shift fork No. 1.

  7. INSPECT GEAR SHIFT FORK NO. 2

    A0136G4E01

    1. Using vernier calipers, inspect gear shift fork No. 2.

      Standard internal diameter and thickness
      A
      9.9 to 10.0 mm (0.3898 to 0.3937 in.)
      B
      14.00 to 14.02 mm (0.5512 to 0.5520 in.)

      If the clearance is outside the specifications, replace gear shift fork No. 2.

  8. INSPECT GEAR SHIFT FORK NO. 3

    A01374UE01

    1. Using vernier calipers, inspect gear shift fork No. 3.

      Standard internal diameter and thickness
      A
      9.9 to 10.0 mm (0.3898 to 0.3937 in.)
      B
      14.00 to 14.02 mm (0.5512 to 0.5520 in.)

      If the clearance is outside the specifications, replace gear shift fork No. 3.

  9. INSPECT GEAR SHIFT HEAD NO. 1

    A01373H

    1. Using vernier calipers, inspect gear shift head No. 1.

      Standard internal diameter
      14.00 to 14.05 mm (0.5512 to 0.5531 in.)
      Maximum internal diameter
      14.05 mm (0.5531 in.)

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

  10. INSPECT GEAR SHIFT HEAD NO. 3

    A01377WE01

    1. Using vernier calipers, inspect gear shift head No. 3.

      Standard internal diameter
      A
      14.00 to 14.05 mm (0.5512 to 0.5531 in.)
      B
      14.2 to 14.4 mm (0.5591 to 0.5669 in.)
      Maximum internal diameter
      A
      14.05 mm (0.5531 in.)
      B
      14.4 mm (0.5669 in.)

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

  11. INSPECT INPUT SHAFT

    A0136VE

    1. Check the input shaft for wear and damage.

    2. 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. A01384SE02

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

      Standard
      Measured Part Outer Diameter mm (in.)
      A 25.502 to 25.515 (1.0040 to 10.0453)
      B 30.985 to 31.000 (1.2199 to 1.2205)
      C, D 33.985 to 34.000 (1.3380 to 1.3386)
      E 23.002 to 23.015 (0.9056 to 0.9091)
      F 22.967 to 23.000 (0.9042 to 0.9055)

      If the outer diameter is below the minimum, replace the input shaft.

  12. INSPECT 3RD GEAR

    A01366B

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

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

      If the internal diameter exceeds the maximum, replace the 3rd gear.

  13. INSPECT 4TH GEAR

    A01366B

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

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

      If the internal diameter exceeds the maximum, replace the 4th gear.

  14. INSPECT 5TH GEAR

    A01366B

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

      Standard internal diameter
      36.015 to 36.031 mm (1.418 to 1.4185 in.)
      Maximum internal diameter
      36.031 mm (1.4185 in.)

      If the internal diameter exceeds the maximum, replace the 5th gear.

  15. INSPECT 3RD GEAR SYNCHRONIZER RING

    A0137FG

    1. Check the 3rd gear for wear and damage.

    2. Check the braking effect of the 3rd gear synchronizer ring. Turn the 3rd gear synchronizer ring in one direction while pushing it against the 3rd gear cone. Check that the ring locks.

    3. A0137JU

      Using a feeler gauge, measure the clearance between the 3rd gear synchronizer ring back and the 3rd 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 below the minimum, replace the 3rd gear synchronizer ring.

  16. INSPECT 4TH GEAR SYNCHRONIZER RING

    A0137FG

    1. Check the 4th gear for wear and damage.

    2. Check the braking effect of the 4th gear synchronizer ring.

      Turn the 4th gear synchronizer ring in one direction while pushing it against the 4th gear cone. Check that the ring locks.

    3. A0137JU

      Using a feeler gauge, measure the clearance between the 4th synchronizer ring back and the 4th 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 below the minimum, replace the 4th gear synchronizer ring.

  17. INSPECT 5TH GEAR SYNCHRONIZER RING

    A0137FG

    1. Check the 5th gear for wear and damage.

    2. Check the braking effect of the 5th gear synchronizer ring.

      Turn the 5th gear synchronizer ring in one direction while pushing it against the 5th gear cone. Check that the ring locks.

    3. A0137JU

      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 below the minimum, replace the 5th gear synchronizer ring.

  18. INSPECT TRANSMISSION HUB SLEEVE NO. 2

    A0135UKE02

    1. Using vernier calipers, measure the clearance between transmission hub sleeve No. 2 and shift fork No. 2.

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

      If the clearance is outside the specifications, replace transmission hub sleeve No. 2 and gear shift fork No. 2.

  19. INSPECT TRANSMISSION HUB SLEEVE NO. 3

    A0137N1E02

    1. Using vernier calipers, measure the clearance between transmission hub sleeve No. 3 and shift fork No. 3.

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

      If the clearance is outside the specifications, replace transmission hub sleeve No. 3 and gear shift fork No. 3.