INPUT SHAFT INSPECTION

INSPECT INPUT SHAFT

Check the input shaft for wear and damage.
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.

Maximum runout
0.03 mm (0.0012 in.)

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 1.0045)
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 0.9061)
F	22.967 to 23.000 (0.9042 to 0.9055)

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

INSPECT 3RD GEAR
1. Using a cylinder gauge, measure the inside diameter of the 3rd gear.
  
  Standard inside diameter
  
  39.015 to 39.031 mm (1.5360 to 1.5367 in.)
  
  Maximum inside diameter
  
  39.031 mm (1.5367 in.)
  
  If the inside diameter exceeds the maximum, replace the 3rd gear.
INSPECT 4TH GEAR
1. Using a cylinder gauge, measure the inside diameter of the 4th gear.
  
  Standard inside diameter
  
  39.015 to 39.031 mm (1.5360 to 1.5367 in.)
  
  Maximum inside diameter
  
  39.031 mm (1.5367 in.)
  
  If the inside diameter exceeds the maximum, replace the 4th gear.
INSPECT 5TH GEAR
1. Using a cylinder gauge, measure the inside diameter of the 5th gear.
  
  Standard inside diameter
  
  36.015 to 36.031 mm (1.4179 to 1.4185 in.)
  
  Maximum inside diameter
  
  36.031 mm (1.4185 in.)
  
  If the inside diameter exceeds the maximum, replace the 5th gear.
INSPECT 3RD GEAR SYNCHRONIZER RING
1. Check 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. 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 (0.0315 to 0.0630 in.)
  
  Minimum clearance
  
  0.80 mm (0.0315 in.)
  
  If the clearance is below the minimum, replace the 3rd gear synchronizer ring.
INSPECT 4TH GEAR SYNCHRONIZER RING
1. Check 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. 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 (0.0315 to 0.0630 in.)
  
  Minimum clearance
  
  0.80 mm (0.0315 in.)
  
  If the clearance is below the minimum, replace the 4th gear synchronizer ring.
INSPECT 5TH GEAR SYNCHRONIZER RING
1. Check 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. 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 (0.0315 to 0.0630 in )
  
  Minimum clearance
  
  0.80 mm (0.0315 in.)
  
  If the clearance is below the minimum, replace the 5th gear synchronizer ring.
INSPECT TRANSMISSION HUB SLEEVE NO.2
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.
INSPECT TRANSMISSION HUB SLEEVE NO.3
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 the transmission hub sleeve No. 3 and gear shift fork No. 3.