OUTPUT SHAFT INSPECTION


  1. INSPECT OUTPUT SHAFT

    A0137RU

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

      Maximum runout
      0.03 mm (0.00118 in.)

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

    2. A0138ZRE01

      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 (1.11)
      D, E 33.985 to 34.000 (1.3380 to 1.3385)
      F 25.002 to 25.015 (0.9844 to 0.9848)

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

  2. INSPECT 1ST GEAR

    A01366S

    1. Using a cylinder gauge, measure the clearance 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 exceeds the maximum, replace the 1st gear.

  3. INSPECT 2ND GEAR

    A0136P2

    1. Using a cylinder gauge, measure the clearance 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 exceeds the maximum, replace the 2nd gear.

  4. INSPECT 1ST GEAR SYNCHRONIZER RING

    A0137Y8

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

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

  5. INSPECT 2ND GEAR SYNCHRONIZER RING

    A0138YZ

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

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

  6. INSPECT REVERSE GEAR

    A0138KCE01

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

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

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