INPUT SHAFT INSPECTION

PROCEDURE


  1. INSPECT INPUT SHAFT


    1. B003K73

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

      Maximum runout
      0.03 mm (0.0012 in.)

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

      Tech Tips

      Measure the 3 areas shown in the illustration with the input shaft level.

    2. B003MVON01

      Using a micrometer, measure the journal diameter of each input shaft journal at the specified positions.

      Standard Journal Diameter
      Item Specified Condition
      Journal A 34.009 to 34.022 mm (1.3390 to 1.3394 in.)
      Journal B 44.985 to 45.000 mm (1.7711 to 1.7716 in.)
      Journal C 44.985 to 45.000 mm (1.7711 to 1.7716 in.)
      Journal D 41.985 to 42.000 mm (1.6530 to 1.6535 in.)
      Journal E 32.967 to 32.98 mm (1.2980 to 1.2984 in.)
      Minimum Diameter
      Item Specified Condition
      Journal A 34.009 mm (1.3389 in.)
      Journal B 44.985 mm (1.7711 in.)
      Journal C 44.985 mm (1.7711 in.)
      Journal D 41.985 mm (1.6530 in.)
      Journal E 32.967 mm (1.2980 in.)

      If the journal diameter is less than the minimum, replace the input shaft.

  2. INSPECT 5TH GEAR


    1. B003PT0

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

      Standard inside diameter
      53.013 to 53.029 mm (2.0872 to 2.0877 in.)
      Maximum inside diameter
      53.029 mm (2.0877 in.)

      If the inside diameter is more than the maximum, replace the 5th gear.

  3. INSPECT 6TH GEAR SUB-ASSEMBLY


    1. B003SCN

      Using a cylinder gauge, measure the inside diameter of the 6th gear sub-assembly.

      Standard inside diameter
      51.015 to 51.040 mm (2.0085 to 2.0094 in.)
      Maximum inside diameter
      51.040 mm (2.0094 in.)

      If the inside diameter is more than the maximum, replace the 6th gear sub-assembly.

  4. INSPECT 3RD GEAR


    1. B003K2Y

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

      Standard inside diameter
      51.015 to 51.040 mm (2.0085 to 2.0094 in.)
      Maximum inside diameter
      51.040 mm (2.0094 in.)

      If the inside diameter is more than the maximum, replace the 3rd gear.

  5. INSPECT NO. 2 TRANSMISSION HUB SLEEVE


    1. B003MT0

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

    2. Check that the splines of the No. 2 transmission hub sleeve are not worn.

    3. B003J2HN02

      Using a vernier caliper, measure the width of the No. 2 transmission hub sleeve groove (A) and the thickness of the claw part of the No. 2 or No. 3 gear shift forks (B), and calculate the clearance.

      Standard Clearance (A - B)
      Item Specified Condition
      No. 2 gear shift fork 0.28 to 0.84 mm (0.0110 to 0.0331 in.)
      No. 3 gear shift fork 0.28 to 0.84 mm (0.0110 to 0.0331 in.)

      If the clearance is outside the specification, replace the No. 2 transmission hub sleeve and gear shift fork.

  6. INSPECT NO. 3 SYNCHRONIZER RING (for 5th Gear)


    1. B003KIK

      Using a feeler gauge, measure the clearance between the No. 3 synchronizer ring and 5th gear.

      Standard clearance
      0.77 to 1.63 mm (0.0304 to 0.0641 in.)
      Minimum clearance
      0.77 mm (0.0304 in.)

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

    2. Coat the 5th gear cone with gear oil.

    3. B003JNK

      Check the braking effect of the synchronizer ring.


      1. Turn the synchronizer ring in both directions while pushing it against the 5th gear cone. Check that the ring locks in both directions. If the No. 3 synchronizer ring turns, replace it.

  7. INSPECT NO. 3 SYNCHRONIZER RING (for 6th Gear)


    1. B003PH3

      Using a feeler gauge, measure the clearance between the No. 3 synchronizer ring and 6th gear.

      Standard clearance
      0.77 to 1.63 mm (0.0304 to 0.0641 in.)
      Minimum clearance
      0.77 mm (0.0304 in.)

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

    2. Coat the 6th gear cone with gear oil.

    3. B003JNK

      Check the braking effect of the synchronizer ring.


      1. Turn the synchronizer ring in both directions while pushing it against the 6th gear cone. Check that the ring locks in both directions. If the No. 3 synchronizer ring turns, replace it.

  8. INSPECT NO. 3 SYNCHRONIZER RING SET


    1. B003RLD

      Using a feeler gauge, measure the clearance between the synchronizer ring and 3rd gear.

      Standard clearance
      0.86 to 2.02 mm (0.0339 to 0.0795 in.)
      Minimum clearance
      0.86 mm (0.0339 in.)

      If the clearance is less than the minimum, replace the No. 3 synchronizer ring set.

    2. Coat the 3rd gear cone with gear oil.

    3. B003P46

      Check the braking effect of the synchronizer ring.


      1. Turn the synchronizer ring in both directions while pushing it against the 3rd gear cone. Check that the ring locks in both directions. If the No. 3 synchronizer ring set turns, replace it.

  9. INSPECT 3RD GEAR THRUST WASHER


    1. B003LVY

      Using a micrometer, measure the 3rd gear thrust washer thickness.

      Standard thickness
      7.62 to 7.68 mm (0.3000 to 0.3023 in.)
      Minimum thickness
      7.62 mm (0.3000 in.)

      If the thickness is less than the minimum, replace the 3rd gear thrust washer.