OUTPUT SHAFT INSPECTION

PROCEDURE

1. INSPECT 1ST GEAR THRUST CLEARANCE

   
   

   1. 

      Using a dial indicator, measure the 1st gear thrust clearance.

      Standard clearance
      0.20 to 0.38 mm (0.00788 to 0.0149 in.)

      Maximum clearance
      0.38 mm (0.0149 in.)

      If the clearance is more than the maximum, replace the No. 1 transmission clutch hub, 1st gear bush or 1st gear. Replace the part or parts determined to be the most likely cause of the problem.

2. INSPECT 2ND GEAR THRUST CLEARANCE

   
   

   1. 

      Using a dial indicator, measure the 2nd gear thrust clearance.

      Standard clearance
      0.15 to 0.33 mm (0.00591 to 0.0129 in.)

      Maximum clearance
      0.33 mm (0.0129 in.)

      If the clearance is more than the maximum, replace the inner 2nd gear bearing race, No. 1 transmission clutch hub, 2nd gear or 3rd driven gear. Replace the part or parts determined to be the most likely cause of the problem.

3. INSPECT 1ST GEAR RADIAL CLEARANCE

   
   

   1. 

      Using a dial indicator, measure the 1st gear radial clearance.

      Standard clearance
      0.009 to 0.045 mm (0.000355 to 0.00177 in.)

      Maximum clearance
      0.045 mm (0.00177 in.)

      If the clearance is more than the maximum, replace the 1st gear, 1st gear needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

4. INSPECT 2ND GEAR RADIAL CLEARANCE

   
   

   1. 

      Using a dial indicator, measure the 2nd gear radial clearance.

      Standard clearance
      0.009 to 0.045 mm (0.000355 to 0.00177 in.)

      Maximum clearance
      0.045 mm (0.00177 in.)

      If the clearance is more than the maximum, replace the 2nd gear, 2nd gear needle roller bearing or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

5. INSPECT OUTPUT SHAFT

   
   

   1. 

      Using a dial indicator and 2 V-blocks, check the output shaft runout.

      Maximum runout
      0.015 mm (0.000590 in.)

      If the runout is more than the maximum, replace the output shaft.

   2. 

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

      Standard outer diameter
      Part A
      30.002 to 30.017 mm (1.1812 to 1.1817 in.)
      Part B
      37.990 to 38.000 mm (1.4957 to 1.4960 in.)
      Part C
      40.790 to 40.800 mm (1.6060 to 1.6062 in.)
      Part D
      28.002 to 28.017 mm (1.1025 to 1.1030 in.)

      Minimum outer diameter
      Part A
      30.002 mm (1.1812 in.)
      Part B
      37.990 mm (1.4957 in.)
      Part C
      40.790 mm (1.6060 in.)
      Part D
      28.002 mm (1.1025 in.)

      If the outer diameter is less than the minimum, replace the output shaft.

6. INSPECT 1ST GEAR

   
   

   1. 

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

      Standard inside diameter
      52.909 to 52.925 mm (2.0831 to 2.0836 in.)

      Maximum inside diameter
      52.925 mm (2.0836 in.)

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

7. INSPECT 2ND GEAR

   
   

   1. 

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

      Standard inside diameter
      52.909 to 52.925 mm (2.0831 to 2.0836 in.)

      Maximum inside diameter
      52.925 mm (2.0836 in.)

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

8. INSPECT 1ST GEAR BUSH

   
   

   1. 

      Using a micrometer, measure the outer diameter of the 1st gear bush.

      Standard outer diameter
      47.89 to 47.90 mm (1.8855 to 1.8858 in.)

      Minimum outer diameter
      47.89 mm (1.8855 in.)

      If the outer diameter is less than the minimum, replace the 1st gear bush.

   2. 

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

      Standard inside diameter
      40.805 to 40.820 mm (1.6065 to 1.6070 in.)

      Maximum inside diameter
      40.820 mm (1.6070 in.)

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

9. INSPECT INNER 2ND GEAR BEARING RACE

   
   

   1. 

      Using a micrometer, measure the outer diameter of the inner 2nd gear bearing race.

      Standard outer diameter
      47.89 to 47.90 mm (1.8855 to 1.8858 in.)

      Minimum outer diameter
      47.89 mm (1.88558 in.)

      If the outer diameter is less than the minimum, replace the inner 2nd gear bearing race.

   2. 

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

      Standard inside diameter
      38.005 to 38.020 mm (1.4963 to 1.4968 in.)

      Maximum inside diameter
      38.020 mm (1.4968 in.)

      If the inside diameter is more than the maximum, replace the inner 2nd gear bearing race.

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

    
    

    1. 

       Text in Illustration

       *1	Outer Ring
       *2	Middle Ring
       *3	Inner Ring

       Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring and outer ring) with gear oil.

    2. Install the inner ring to the 1st gear.

    3. Install the middle ring to the 1st gear.

    4. Install the outer ring to the 1st gear.

    5. 

       Check for wear and damage.

    6. Turn the synchronizer ring in both directions while pushing it against the 1st gear cone and check that it locks in both directions.

       If the synchronizer ring does not lock, replace the synchronizer ring.

    7. 

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

       Standard clearance
       0.915 to 1.855 mm (0.0361 to 0.0730 in.)

       Minimum clearance
       0.915 mm (0.0361 in.)

       If the clearance is less than the minimum, replace the synchronizer ring set.

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

    
    

    1. Coat the 2nd gear cone and No. 1 synchronizer ring set (inner ring, middle ring and outer ring) with gear oil.

    2. 

       Install the inner ring to the 2nd gear.

    3. Install the middle ring to the 2nd gear.

    4. Install the outer ring to the 2nd gear.

    5. 

       Check for wear and damage.

    6. Turn the synchronizer ring in both directions while pushing it against the 2nd gear cone and check that it locks in both directions.

       If the synchronizer ring does not lock, replace the synchronizer ring.

    7. 

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

       Standard clearance
       0.92 to 1.86 mm (0.0363 to 0.0732 in.)

       Minimum clearance
       0.92 mm (0.0363 in.)

       If the clearance is less than the minimum, replace the synchronizer ring set.

12. INSPECT REVERSE GEAR

    
    
    1. 

       *1	Clearance = A - B

       Using a vernier caliper, measure the width of the reverse gear groove (A) and the thickness of the claw part on the No. 1 gear shift fork shaft assembly (B), and calculate the clearance.

       Standard clearance (A - B)
       0.1 to 0.5 mm (0.00394 to 0.0196 in.)

       If the clearance is not as specified, replace the reverse gear and No. 1 gear shift fork shaft assembly.

13. INSPECT NO. 1 TRANSMISSION CLUTCH HUB

    
    

    1. 

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

    2. Check that the edges of the reverse gear spline gear are not worn down.