OUTPUT 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 OUTPUT SHAFT

    A0137RU

    1. Using a dial indicator, check the shaft runout.

      Maximum runout
      0.03 mm (0.0012 in.)

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

    2. A0138ZRE02

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

      Standard
      Measured Part Outer Diameter mm (in.)
      A 23.002 to 23.015 (0.9056 to 0.9061)
      B, C 28.3 (1.1142)
      D, E 33.985 to 34.000 (1.3380 to 1.3386)
      F 25.002 to 25.015 (0.9843 to 0.9847)

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

  12. INSPECT 1ST GEAR

    A01366S

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

  13. INSPECT 2ND GEAR

    A0136P2

    1. Using a cylinder gauge, measure the clearance of the 2nd 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 2nd gear.

  14. INSPECT 1ST GEAR SYNCHRONIZER RING

    A0137Y8

    1. Check the 1st gear for wear and damage.

    2. Check the braking effect of the 1st gear synchronizer ring.

      Turn the 1st gear synchronizer ring in one direction while pushing it against the 1st gear cone. Check that the ring locks.

    3. A0136VH

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

      Standard clearance
      0.8 to 1.6 mm (0.031 to 0.063 in.)
      Minimum clearance
      0.80 mm (0.031 in.)

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

  15. INSPECT 2ND GEAR SYNCHRONIZER RING

    A0138YZ

    1. Check the 2nd gear for wear and damage.

    2. Check the braking effect of the 2nd gear synchronizer ring.

      Turn the 2nd gear synchronizer ring in one direction while pushing it against the 2nd gear cone. Check that the ring locks.

    3. A0135Z4

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

      Standard clearance
      0.8 to 1.6 mm (0.031 to 0.063 in.)
      Minimum clearance
      0.80 mm (0.031 in.)

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

  16. INSPECT REVERSE GEAR

    A0138KCE02

    1. Using vernier calipers, measure the clearance between the reverse gear and the reverse gear fork.

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

      If the clearance is outside the specifications, replace the reverse gear fork and reverse gear.