OUTPUT SHAFT INSPECTION

PROCEDURE

1. INSPECT 1ST GEAR THRUST CLEARANCE

   
   

   1. 

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

      Standard clearance
      0.23 to 0.37 mm (0.00906 to 0.01456 in.)

      Maximum clearance
      0.37 mm (0.01456 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
      0.16 to 0.33 mm (0.00630 to 0.01299 in.)

      Maximum clearance
      0.33 mm (0.01299 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 0.047 mm (0.00036 to 0.00185 in.)

      Maximum clearance
      0.047 mm (0.00185 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 0.047 mm (0.00036 to 0.00185 in.)

      Maximum clearance
      0.047 mm (0.00185 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, 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.

   2. 

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

      Standard journal diameter
      Journal A
      28.010 to 28.023 mm (1.1028 to 1.1032 in.)
      Journal B
      42.180 to 42.200 mm (1.6607 to 1.6614 in.)
      Journal C
      36.010 to 36.026 mm (1.4178 to 1.4183 in.)

      Minimum journal diameter
      Journal A
      28.010 mm (1.1028 in.)
      Journal B
      42.180 mm (1.6607 in.)
      Journal C
      36.010 mm (1.4178 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
      57.909 to 57.925 mm (2.2799 to 2.2805 in.)

      Maximum inside diameter
      57.925 mm (2.2805 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
      57.909 to 57.925 mm (2.2799 to 2.2805 in.)

      Maximum inside diameter
      57.925 mm (2.2805 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
      51.890 to 51.900 mm (2.0430 to 2.0433 in.)

      Minimum outer diameter
      51.890 mm (2.0430 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
      42.200 to 42.215 mm (1.6615 to 1.6620 in.)

      Maximum inside diameter
      42.215 mm (1.6620 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
      51.890 to 51.900 mm (2.0430 to 2.0433 in.)

      Minimum outer diameter
      51.890 mm (2.0430 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
      42.200 to 42.215 mm (1.6615 to 1.6620 in.)

      Maximum inside diameter
      42.215 mm (1.6620 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. Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring and outer ring) with gear oil.

    2. 

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

       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. 

       *a	Locks in both directions

       Check for wear and damage.

    6. Turn the No. 1 synchronizer ring set in both directions while pushing it against the 1st gear cone and check that it locks in both directions.

       If the No. 1 synchronizer ring set does not lock, replace the No. 1 synchronizer ring set.

    7. 

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

       Standard clearance
       0.88 to 1.72 mm (0.0347 to 0.0677 in.)

       Minimum clearance
       0.88 mm (0.0347 in.)

       If the clearance is less than the minimum, replace the No. 1 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. 

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

       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. 

       *a	Locks in both directions

       Check for wear and damage.

    6. Turn the No. 1 synchronizer ring set in both directions while pushing it against the 2nd gear cone and check that it locks in both directions.

       If the No. 1 synchronizer ring set does not lock, replace the No. 1 synchronizer ring set.

    7. 

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

       Standard clearance
       0.88 to 1.72 mm (0.0347 to 0.0677 in.)

       Minimum clearance
       0.88 mm (0.0347 in.)

       If the clearance is less than the minimum, replace the No. 1 synchronizer ring set.

12. INSPECT REVERSE GEAR

    
    
    1. 

       *a	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 0.01968 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.