MANUAL TRANSMISSION UNIT INSPECTION

PROCEDURE

1. INSPECT REVERSE IDLER GEAR RADIAL CLEARANCE

   
   

   1. 

      Using a dial indicator, measure the radial clearance.

      Standard clearance
      0.015 to 0.050 mm (0.000591 to 0.00196 in.)

      Maximum clearance
      0.050 mm (0.00196 in.)

      If the clearance is more than the maximum, replace the needle roller bearing.

2. INSPECT NO. 4 SYNCHRONIZER RING

   
   

   1. 

      Using a feeler gauge, measure the clearance between the No. 4 synchronizer ring and gear spline.

      Standard Clearance
      0.82 to 1.48 mm (0.0323 to 0.0582 in.)

      Minimum Clearance
      0.82 mm (0.0323 in.)

      If the clearance is less than the minimum, replace the No. 4 synchronizer ring.

   2. Coat the output shaft cone with gear oil.

   3. 

      Check the braking effect of the synchronizer ring.

      
      

      1. Turn the synchronizer ring in both directions while pushing it against the output shaft cone. Check that the ring locks in both directions. If No. 4 synchronizer ring turns, replace it.

3. INSPECT REVERSE IDLER GEAR

   
   

   1. Install the reverse idler gear with the reverse idler gear shaft bolt.

      Torque:

      25 N*m  { 255 kgf*cm, 18 ft.*lbf }

   2. 

      Using a feeler gauge, measure the thrust clearance.

      Standard clearance
      0.196 to 0.939 mm (0.0078 to 0.0369 in.)

      Maximum clearance
      0.939 mm (0.0369 in.)

      If the clearance is more than the maximum, replace the reverse idler gear shaft, reverse idler gear or transmission case.

   3. Remove the reverse idler gear.