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OUTPUT SHAFT INSPECTION

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  1. Click here

    INSPECT OUTPUT SHAFT


    1. A01DPY9E01

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

      Standard Journal diameter
      Item Specified Condition
      Journal A 34.984 to 35.000 mm (1.3774 to 1.3779 in.)
      Journal B 37.984 to 38.000 mm (1.4955 to 1.4960 in.)
      Journal C 30.384 to 30.400 mm (1.1963 to 1.1968 in.)

      • If the result is not as specified, replace the output shaft.

    2. A01DP9LE01

      Using a micrometer, measure the flange thickness.

      Standard thickness
      4.80 to 5.20 mm (0.189 to 0.204 in.)
      Minimum thickness
      4.80 mm (0.189 in.)

      • If the thickness is clearance less than the minimum, replace the output shaft.

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    INSPECT 1ST GEAR BEARING INNER RACE


    1. A01DQPOE01

      Using a micrometer, measure the inner race thickness.

      Standard thickness
      3.995 to 4.195 mm (0.158 to 0.165 in.)
      Minimum thickness
      3.995 mm (0.158 in.)

      • If the thickness is less than the minimum, replace the 1st gear bearing inner race.

    2. A01DMUYE01

      Using a micrometer, measure the outside diameter of the inner race.

      Standard outside diameter
      38.985 to 39.000 mm (1.5349 to 1.5354 in.)
      Minimum outside diameter
      38.985 mm (1.5349 in.)

      • If the outside diameter is less than the minimum, replace the 1st gear bearing inner race.

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    INSPECT NO. 1 SYNCHRONIZER RING (for 1st Gear)


    1. A01DMI3E01

      Coat the 1st gear cone with gear oil.

    2. Check the braking effect of the No. 1 synchronizer ring.


      1. Install the ring to the shaft cone.

      2. Apply pressure to the ring and attempt to turn it in both directions. Check that the ring locks.


        • If the braking effect is insufficient, apply a small amount of fine lapping compound between the No. 1 synchronizer ring and the 1st gear cone. Lightly rub the No. 1 synchronizer ring and the 1st gear cone together. Check the braking effect of the No. 2 synchronizer ring again.

          Note:

          Make sure the fine lapping compound is completely washed off after rubbing.

    3. A01DO6DE01

      Using a feeler gauge, measure the clearance between the No. 1 synchronizer ring back and 1st gear spline end.

      Standard clearance
      1.00 to 2.00 mm (0.0394 to 0.0787 in.)

      • If the result is not as specified, replace the No. 1 synchronizer ring and apply a small amount of fine lapping compound to the 1st gear cone.

        Note:

        Make sure the fine lapping compound is completely washed off after rubbing.

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    INSPECT NO. 1 SYNCHRONIZER RING (for 2nd Gear)


    1. A01DSSOE01

      Coat the 2nd gear cone with gear oil.

    2. Check the braking effect of the No. 1 synchronizer ring.


      1. Install the ring to the shaft cone.

      2. Apply pressure to the ring and attempt to turn it in both directions. Check that the ring locks.


        • If the braking effect is insufficient, apply a small amount of fine lapping compound between the No. 1 synchronizer ring and the 2nd gear cone. Lightly rub the No. 1 synchronizer ring and the 2nd gear cone together. Check the braking effect of the No. 2 synchronizer ring again.

          Note:

          Make sure the fine lapping compound is completely washed off after rubbing.

    3. A01DQ1AE01

      Using a feeler gauge, measure the clearance between the No. 1 synchronizer ring back and 2nd gear spline end.

      Standard clearance
      1.00 to 2.00 mm (0.0394 to 0.0787 in.)

      • If the result is not as specified, replace the No. 1 synchronizer ring, and apply a small amount of fine lapping compound to the 2nd gear cone.

        Note:

        Make sure the fine lapping compound is completely washed off after rubbing.

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    INSPECT NO. 2 SYNCHRONIZER RING


    1. A01DSHKE01

      Coat the 3rd gear cone with gear oil.

    2. Check the braking effect of the No. 2 synchronizer ring.


      1. Install the ring to the shaft cone.

      2. Apply pressure to the ring and attempt to turn it in both directions. Check that the ring locks.


        • If the braking effect is insufficient, apply a small amount of fine lapping compound between the No. 2 synchronizer ring and the 3rd gear cone. Lightly rub the No. 2 synchronizer ring and the 3rd gear cone together. Check the braking effect of the No. 2 synchronizer ring again.

          Note:

          Make sure the fine lapping compound is completely washed off after rubbing.

    3. A01DTLFE02

      Using a feeler gauge, measure the clearance between the No. 2 synchronizer ring back and 3rd gear spline end.

      Standard clearance
      1.0 to 2.0 mm (0.0394 to 0.0787 in.)

      • If the result is not as specified, replace the No. 2 synchronizer ring and apply a small amount of fine lapping compound to the 3rd gear cone.

        Note:

        Make sure the fine lapping compound is completely washed off after rubbing.

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    INSPECT REVERSE GEAR


    1. A01DNEQE01

      Using a vernier caliper, measure the clearance between the reverse gear and No. 1 gear shift fork.

      Standard clearance
      0.15 to 0.35 mm (0.00591 to 0.0137 in.)
      Maximum clearance
      0.35 mm (0.0137 in.)

      • If the clearance is more than the maximum, replace the No. 1 gear shift fork and reverse gear.

    2. A01DSYVE01

      Check that the No. 1 transmission clutch hub and reverse gear slide smoothly.

    3. Check that the splines of the reverse gear are not worn down.

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    INSPECT NO. 2 TRANSMISSION HUB SLEEVE


    1. A01DR4HE02

      Using a vernier caliper, measure the No. 2 hub sleeve and No. 2 gear shift fork as shown in the illustration.

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

      • If the result is not as specified, replace the transmission hub sleeve and the No. 2 gear shift fork.

    2. A01DN81E01

      Check the sliding condition between the No. 2 hub sleeve and No. 2 clutch hub.

    3. Check that the splines of the No. 2 transmission hub sleeve are not worn down.

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    INSPECT 1ST GEAR


    1. A01DOAKE01

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

      Standard inside diameter
      44.015 to 44.040 mm (1.7329 to 1.7338 in.)
      Maximum inside diameter
      44.040 mm (1.7338 in.)

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

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    INSPECT 2ND GEAR


    1. A01DM57E01

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

      Standard inside diameter
      44.015 to 44.040 mm (1.7329 to 1.7338 in.)
      Maximum inside diameter
      44.040 mm (1.7338 in.)

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

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    INSPECT 3RD GEAR


    1. A01DTMSE01

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

      Standard inside diameter
      44.015 to 44.040 mm (1.7329 to 1.7338 in.)
      Maximum inside diameter
      44.040 mm (1.7338 in.)

      • If the inside diameter is more than the maximum, replace the 3rd gear.