MANUAL TRANSMISSION UNIT INSPECTION


  1. INSPECT COUNTER SHAFT 5TH GEAR THRUST CLEARANCE


    1. A003CEY

      Using a feeler gauge, measure the counter shaft 5th gear thrust clearance.

      Standard clearance
      0.10 to 0.35 mm (0.0039 to 0.0138 in.)

  2. INSPECT COUNTER SHAFT 5TH GEAR RADIAL CLEARANCE


    1. A003ESM

      Using a dial indicator, measure the radial clearance of the counter shaft 5th gear.

      Standard clearance
      0.015 to 0.068 mm (0.0059 to 0.0027 in.)

      If the clearance is not within the specified values, replace the counter 5th gear bearing with a new one.

  3. INSPECT SYNCHRONIZER RING OUTER NO.3


    1. A003G7G

      Apply gear oil to the cone part of the gear spline piece No.5, and check that it does not turn in either direction while pushing the synchronizer ring outer No.3 against the gear spline piece No.5.

      If it turns, replace the synchronizer ring.

    2. A003C97

      Measure the clearance between the synchronizer ring outer No.3 and gear spline piece No.5 while pushing the synchronizer ring outer No.3 against the cone part of the gear spline piece No.5.

      Standard clearance
      0.68 to 1.32 mm (0.0267 to 0.0610 in.)

      If the clearance is not within the specified values, replace the synchronizer ring outer No.3 with a new one.

  4. INSPECT TRANSMISSION HUB SLEEVE NO.3


    1. A003GN3

      Check that the counter shaft 5th gear and transmission hub sleeve No.3 slide smoothly each other.

    2. Check the tip of the spline gear of the transmission hub sleeve No.3 for wear.

      If there are any defects, replace the transmission hub sleeve No.3.

    3. A003C7EE04

      Using vernier calipers, measure the width of the transmission hub sleeve No.3 groove and the thickness of the claw part of the shift fork No.3, and calculate the clearance.

      Standard clearance (A - B)
      0.26 to 0.84 mm (0.0102 to 0.0331 in.)

      If the clearance is not within the specified values, replace the transmission hub sleeve No.3 and shift fork No.3 with new ones.

  5. INSPECT COUNTER SHAFT 5TH GEAR


    1. A003CQN

      Using a cylinder gauge, measure the inner diameter of the counter 5th gear.

      Standard diameter
      38.015 to 38.040 mm (1.4967 to 1.4976 in.)
      Maximum diameter
      38.040 mm (1.4976 in.)

      If the diameter is greater than the maximum, replace the counter shaft 5th gear with a new one.

  6. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY


    1. A003EYE

      Using a caliper gauge, measure the inner diameter of the reverse idler gear.

      Standard diameter
      24.040 to 24.061 mm (0.9465 to 0.9473 in.)
      Maximum diameter
      24.061 mm (0.9473 in.)

      If the diameter is greater than the maximum, replace the reverse idler gear with a new one.

    2. Using a micrometer, measure the outer diameter of the sliding part of the reverse idler gear on the reverse idler gear shaft.

      Standard diameter
      23.979 to 24.000 mm (0.9441 to 0.9449 in.)
      Minimum diameter
      23.979 mm (0.9441 in.)

      If the diameter is less than the minimum, replace the reverse idler gear shaft with a new one.

    3. Subtract the reverse idler gear shaft inside diameter from the reverse idler gear diameter clearance.

      Standard clearance
      0.040 to 0.082 mm (0.0016 to 0.0032 in.)

      If the clearance is not as specified, replace the reverse idler gear and reverse idler gear shaft.

    4. A003GVP

      Using a feeler gauge, measure the thrust clearance of the shoe part between the reverse idler gear and the reverse shift arm.

      Standard clearance
      0.05 to 0.35 mm (0.0020 to 0.0138 in.)

      If the clearance is outside the specification, replace the idler gear and reverse shift arm with new ones.