MANUAL TRANSAXLE UNIT INSPECTION

PROCEDURE


  1. INSPECT NO. 1 GEAR SHIFT HEAD


    1. A004H2H

      Using a vernier caliper, measure the clearance of the No. 1 gear shift head groove.

      Standard clearance
      15.2 to 15.4 mm (0.59843 to 0.60630 in.)
      Maximum clearance
      15.4 mm (0.60630 in.)

      Tech Tips

      If the clearance exceeds the maximum, replace the No. 1 gear shift head with a new one.

  2. INSPECT NO. 2 GEAR SHIFT HEAD


    1. A004HUC

      Using a vernier caliper, measure the clearance of the No. 2 gear shift head groove.

      Standard clearance
      15.2 to 15.4 mm (0.59843 to 0.60630 in.)
      Maximum clearance
      15.4 mm (0.60630 in.)

      Tech Tips

      If the clearance exceeds the maximum, replace the No. 2 gear shift head with a new one.

  3. INSPECT NO. 3 GEAR SHIFT HEAD


    1. A004KPI

      Using a vernier caliper, measure the clearance of the No. 3 gear shift head groove.

      Standard clearance
      15.2 to 15.4 mm (0.598 to 0.606 in.)
      Maximum clearance
      15.4 mm (0.606 in.)

      Tech Tips

      If the clearance exceeds the maximum, replace the No. 3 gear shift head with a new one.

  4. INSPECT SHIFT SHAFT


    1. A004IIX

      Using a vernier caliper, measure the claw width of the shift shaft.

      Standard width
      14.8 to 15.0 mm (0.583 to 0.591 in.)
      Minimum width
      14.8 mm (0.583 in.)

      Tech Tips

      If the width is less than the minimum, replace the gear shift with a new one.

  5. INSPECT NO. 1 SHIFT INTER LOCK BLOCK


    1. A004HRE

      Using a vernier caliper, measure the claw width of the No. 1 shift inter lock block.

      Standard width
      14.8 to 15.0 mm (0.583 to 0.591 in.)
      Minimum width
      14.8 mm (0.583 in.)

      Tech Tips

      If the width is less than the minimum, replace the No. 1 shift inter lock block.

  6. INSPECT NO. 4 GEAR SHIFT FORK


    1. A004IJG

      Using a vernier caliper, measure the clearance of the No. 4 gear shift fork groove.

      Standard clearance
      15.2 to 15.4 mm (0.598 to 0.606 in.)
      Maximum clearance
      15.4 mm (0.606 in.)

      Tech Tips

      If the clearance exceeds the maximum, replace the No. 4 gear shift fork with a new one.

  7. INSPECT 5TH SHIFT HEAD


    1. A004JF4

      Using a vernier caliper, measure the clearance of the 5th shift head groove.

      Standard clearance
      15.2 to 15.4 mm (0.598 to 0.606 in.)
      Maximum clearance
      15.4 mm (0.606 in.)

      Tech Tips

      If the clearance exceeds the maximum, replace the 5th shift head with a new one.

  8. INSPECT NO. 2 SYNCHRONIZER RING


    1. A004JCW

      Apply manual transmission gear oil to the taper cone of the counter shaft 6th gear, and then hold the No. 2 synchronizer ring in position with your hand to measure the clearance between the No. 2 synchronizer ring and counter shaft 6th gear by using a feeler gauge.

      Standard clearance
      0.88 to 1.52 mm (0.0346 to 0.0598 in.)
      Minimum clearance
      0.88 mm (0.0346 in.)

      Note

      Check the entire circumference of the gear.

      Tech Tips

      If the clearance is less than the minimum, replace the No. 2 synchronizer ring and counter shaft 6th gear with a new one.

    2. A004JJ0

      Apply manual transmission gear oil to the taper cone of the counter shaft 6th gear, and then hold the No. 2 synchronizer ring in position with your hand to check that it does not slide in the circumferential direction.

      Tech Tips

      If the No. 2 synchronizer ring slides, replace the No. 2 synchronizer ring and counter shaft 6th gear with a new one.

  9. INSPECT COUNTER SHAFT 6TH GEAR


    1. A004KOP

      Using a cylinder gauge, measure the inside diameter of the counter shaft 6th gear.

      Standard inside diameter
      34.015 to 34.040 mm (1.33917 to 1.34016 in.)
      Maximum inside diameter
      34.040 mm (1.34016 in.)

      Tech Tips

      If the inside diameter exceeds the maximum, replace the counter shaft 6th gear with a new one.

  10. INSPECT NO. 4 TRANSMISSION HUB SLEEVE


    1. A004J72

      Check that the spline gear edges of the No. 4 transmission hub sleeve are not worn down.

      Tech Tips

      If it shows any sign of wear, replace the No. 4 transmission hub sleeve with a new one.

    2. Install the No. 4 transmission hub sleeve to the No. 4 transmission clutch hub, and then check that it slides smoothly.

      Tech Tips

      If it does not slide smoothly, replace the No. 4 transmission hub sleeve and No. 4 transmission clutch hub with a new one.

  11. INSPECT NO. 4 TRANSMISSION HUB SLEEVE CLEARANCE


    1. A004IY6

      Using a vernier caliper, measure the claw width of the No. 4 gear shift fork.

      Standard width
      7.9 to 8.0 mm (0.311 to 0.315 in.)
      Minimum width
      7.9 mm (0.311 in.)

      Tech Tips

      If the width is less than the minimum, replace the gear No. 4 shift fork with a new one.

    2. Using a vernier caliper, measure the groove of the No. 4 transmission hub sleeve and then calculate the clearance with the No. 4 gear shift fork.

      Standard clearance
      0.15 to 0.35 mm (0.00590 to 0.0138 in.)
      Maximum clearance
      0.35 mm (0.0138 in.)

      Tech Tips

      If the clearance exceeds the maximum, replace both the No. 4 gear shift fork and No. 4 transmission hub sleeve with a new ones.

  12. INSPECT REVERSE IDLER GEAR


    1. A004HPL

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

      Standard inside diameter
      22.040 to 22.061mm (0.86771 to 0.86854 in.)
      Maximum inside diameter
      22.061mm (0.86854 in.)

      Tech Tips

      If the inside diameter exceeds the maximum, replace the reverse idler gear with a new one.

  13. INSPECT REVERSE IDLER GEAR SHAFT


    1. A004HF9

      Using a micrometer, measure the outer diameter of the reverse idler gear shaft.

      Standard outer diameter
      21.979 to 22.000 mm (0.86531 to 0.86614 in.)
      Minimum outer diameter
      21.979 mm (0.86531 in.)

      Tech Tips

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