OUTPUT SHAFT INSPECTION

PROCEDURE


  1. INSPECT OUTPUT SHAFT


    1. A01XDT7

      Using a dial indicator, measure the output shaft runout.

      Maximum runout
      0.03 mm (0.00118 in.)

      • If the runout is more than the maximum, replace the output shaft with a new one.

    2. A01XIDSE01

      Using a micrometer, measure the journal diameter at A, B and C on the output shaft.

      Standard Journal Diameter
      Item Specified Condition
      Journal A 38.979 to 38.995 mm (1.5346 to 1.5352 in.)
      Journal B 46.984 to 47.000 mm (1.8498 to 1.8504 in.)
      Journal C 37.984 to 38.000 mm (1.4954 to 1.4961 in.)

      • If the diameter is not as specified, replace the output shaft with a new one.

    3. A01XH9I

      Using a micrometer, measure the thickness of the output shaft flange as shown in the illustration.

      Standard thickness
      4.8 to 5.2 mm (0.189 to 0.204 in.)

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

  2. INSPECT 3RD GEAR


    1. A01XLTX

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

      Standard inside diameter
      44.015 to 44.040 mm (1.7329 to 1.7339 in.)
      Maximum inside diameter
      44.040 mm (1.7339 in.)

      • If the inside diameter is more than the maximum, replace the 3rd gear with a new one.

  3. INSPECT 2ND GEAR


    1. A01XG0H

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

      Standard inside diameter
      53.015 to 53.040 mm (2.0872 to 2.0881 in.)
      Maximum inside diameter
      53.040 mm (2.0881 in.)

      • If the inside diameter is more than the maximum, replace the 2nd gear with a new one.

  4. INSPECT 1ST GEAR


    1. A01XHTV

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

      Standard inside diameter
      46.015 to 46.040 mm (1.812 to 1.8126 in.)
      Maximum inside diameter
      46.040 mm (1.8126 in.)

      • If the inside diameter is more than the maximum, replace the 1st gear with a new one.

  5. INSPECT 1ST GEAR THRUST WASHER


    1. A01XI1A

      Using a micrometer, measure the thickness of the thrust washer.

      Standard thickness
      5.95 to 6.05 mm (0.235 to 0.238 in.)
      Minimum thickness
      5.95 mm (0.235 in.)

      • If the thickness is less than the minimum, replace the 1st gear thrust washer.

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


    1. A01XJRH

      Apply gear oil to the cone of the 1st gear, and check that the No. 1 synchronizer ring set does not turn in either direction while pushing the No. 1 synchronizer ring set.


      • If No. 1 synchronizer ring set turns, replace it.

    2. A01XF77

      Measure the clearance between the No. 1 synchronizer ring and 1st gear while pushing the No. 1 synchronizer ring against the cone of the 1st gear.

      Standard clearance
      0.75 to 1.65 mm (0.0295 to 0.0650 in.)

      • If the clearance is not as specified, replace the No. 1 synchronizer ring with a new one.

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


    1. A01XESR

      Apply gear oil to the cone of the 2nd gear, and check that No. 1 synchronizer ring set does not turn in either direction while pushing the No. 1 synchronizer ring set.


      • If No. 1 synchronizer ring set turns, replace it.

    2. A01XF8U

      Push the No. 1 synchronizer ring set against the cone of the 2nd gear. Measure the clearance between the No. 1 synchronizer ring set and 2nd gear.

      Standard clearance
      0.65 to 1.75 mm (0.0256 to 0.0689 in.)

      • If the clearance is not as specified, replace the No. 1 synchronizer ring with a new one.

  8. INSPECT NO. 2 SYNCHRONIZER RING (for 3rd Gear)


    1. A01XGIW

      Apply gear oil to the cone of the 3rd gear, and check that No. 2 synchronizer ring does not turn in either direction while pushing the No. 2 synchronizer ring.


      • If the No. 2 synchronizer ring turns, replace it.

    2. A01XIXP

      Push the No. 2 synchronizer ring against the cone of the 3rd gear. Measure the clearance between the No. 2 synchronizer ring (for the 3rd gear) and 3rd gear.

      Standard clearance
      0.75 to 1.65 mm (0.0295 to 0.0650 in.)

      • If the clearance is not as specified, replace the No. 2 synchronizer ring with a new one.

  9. INSPECT REVERSE GEAR


    1. A01XL3E

      Using a vernier caliper, measure the groove of the No. 1 shift fork and the thickness of flange of the reverse gear. Then calculate the clearance between the No. 1 shift fork and flange.

      Standard clearance
      0.15 to 0.41 mm (0.00591 to 0.0161 in.)

      • If the clearance is not as specified, replace the reverse gear and No. 1 shift fork with new ones.

  10. INSPECT NO. 1 TRANSMISSION CLUTCH HUB


    1. A01XHMW

      Check the sliding condition between the No. 1 clutch hub and reverse gear.

    2. Check the spline of the reverse gear for wear.


      • If there are any defects, replace the No. 1 clutch hub.

  11. INSPECT NO. 2 TRANSMISSION HUB SLEEVE


    1. A01XKS3

      Using a vernier caliper, measure the groove of the No. 2 hub sleeve and the thickness of claw of the No. 2 shift fork. Then calculate the clearance between the No. 2 hub sleeve and the claw.

      Standard clearance
      0.15 to 0.35 mm (0.00591 to 0.0138 in.)

      • If the clearance is not as specified, replace the No. 2 hub sleeve and No. 2 shift fork with new ones.

  12. INSPECT TRANSMISSION CLUTCH HUB NO. 2


    1. A01XHB6

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

    2. Check the splines of the No. 1 clutch hub for wear.

    3. Check the tip of the spline gear sleeve of the reverse gear for wear.


      • If there are any defects, replace the No. 1 clutch hub or reverse gear.