INPUT SHAFT INSPECTION

PROCEDURE


  1. INSPECT 6TH GEAR THRUST CLEARANCE


    1. A001U9R

      Using a dial indicator, measure the 6th gear thrust clearance.

      Standard Clearance
      0.15 to 0.43 mm (0.00591 to 0.0169 in.)
      Maximum Clearance
      0.43 mm (0.0169 in.)

      If the clearance exceeds the maximum, replace the No. 3 transmission clutch hub, 6th gear sub-assembly or input shaft.

  2. INSPECT 5TH GEAR THRUST CLEARANCE


    1. A001ULZ

      Using a dial indicator, measure the 5th gear thrust clearance.

      Standard Clearance
      0.15 to 0.43 mm (0.00591 to 0.0169 in.)
      Maximum Clearance
      0.43 mm (0.0169 in.)

      If the clearance exceeds the maximum, replace the No. 3 transmission clutch hub, 5th gear or input shaft.

  3. INSPECT 4TH GEAR THRUST CLEARANCE


    1. A001Y5Z

      Using a dial indicator, measure the 4th gear thrust clearance.

      Standard Clearance
      0.15 to 0.56 mm (0.00591 to 0.0220 in.)
      Maximum Clearance
      0.56 mm (0.0220 in.)

      If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 4th gear or input shaft.

  4. INSPECT 3RD GEAR THRUST CLEARANCE


    1. A001W8R

      Using a dial indicator, measure the 3rd gear thrust clearance.

      Standard Clearance
      0.15 to 0.43 mm (0.00591 to 0.0169 in.)
      Maximum Clearance
      0.43 mm (0.0169 in.)

      If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 3rd gear or input shaft.

  5. INSPECT 6TH GEAR RADIAL CLEARANCE


    1. A001XH0

      Using a dial indicator, measure the 6th gear radial clearance between the gear and shaft.

      Standard Clearance
      0.009 to 0.045 mm (0.000354 to 0.00177 in.)
      Maximum Clearance
      0.045 mm (0.00177 in.)

      If the clearance exceeds the maximum, replace the 6th gear sub-assembly, 6th gear needle roller bearing, inner 6th gear bearing race or input shaft.

  6. INSPECT 5TH GEAR RADIAL CLEARANCE


    1. A001WCF

      Using a dial indicator, measure the 5th gear radial clearance between the gear and shaft.

      Standard Clearance
      0.009 to 0.045 mm (0.000354 to 0.00177 in.)
      Maximum Clearance
      0.045 mm (0.00177 in.)

      If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing, inner 5th gear bearing race or input shaft.

  7. INSPECT 4TH GEAR RADIAL CLEARANCE


    1. A001WK3

      Using a dial indicator, measure the 4th gear radial clearance between the gear and shaft.

      Standard Clearance
      0.009 to 0.050 mm (0.000354 to 0.0197 in.)
      Maximum Clearance
      0.050 mm (0.0197 in.)

      If the clearance exceeds the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft.

  8. INSPECT 3RD GEAR RADIAL CLEARANCE


    1. A001XQN

      Using a dial indicator, measure the 3rd gear radial clearance.

      Standard Clearance
      0.009 to 0.050 mm (0.000354 to 0.0197 in.)
      Maximum Clearance
      0.050 mm (0.0197 in.)

      If the clearance exceeds the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft.

  9. INSPECT INPUT SHAFT


    1. A001T0J

      Using a dial indicator, check the input shaft runout.

      Maximum Runout
      0.03 mm (0.00118 in.)

      If the runout exceeds the maximum, replace the input shaft.

    2. A001SZNN13

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

      Standard Outer Diameter
      Part A
      25.002 to 25.017 mm (0.9843 to 0.9849 in.)
      Part B
      37.485 to 37.500 mm (1.4758 to 1.4764 in.)
      Part C
      37.496 to 37.500 mm (1.4762 to 1.4764 in.)
      Part D
      31.690 to 31.700 mm (1.2476 to 1.2480 in.)
      Part E
      27.990 to 28.000 mm (1.1019 to 1.1023 in.)
      Minimum Outer Diameter
      Part A
      25.002 mm (0.9843 in.)
      Part B
      37.485 mm (1.4757 in.)
      Part C
      37.496 mm (1.4762 in.)
      Part D
      31.690 mm (1.2476 in.)
      Part E
      27.990 mm (1.1019 in.)

      If any of the outer diameters are less than the minimum, replace the input shaft.

  10. INSPECT INNER 6TH GEAR BEARING RACE


    1. A001WZE

      Using a micrometer, measure the outer diameter of the inner 6th gear bearing race.

      Standard Outer Diameter
      35.09 to 35.10 mm (1.3814 to 1.3818 in.)
      Minimum Outer Diameter
      35.09 mm (1.3814 in.)

      If the outer diameter is less than the minimum, replace the inner 6th gear bearing race.

    2. A001VZR

      Using a cylinder gauge, measure the inside diameter of the inner 6th gear bearing race.

      Standard Inside Diameter
      28.005 to 28.020 mm (1.1025 to 1.1031 in.)
      Maximum Inside Diameter
      28.020 mm (1.1031 in.)

      If the inside diameter exceeds the maximum, replace the inner 6th gear bearing race.

  11. INSPECT INNER 5TH GEAR BEARING RACE


    1. A001YE1

      Using a micrometer, measure the outer diameter of the inner 5th gear bearing race.

      Standard Outer Diameter
      37.49 to 37.50 mm (1.4759 to 1.4763 in.)
      Minimum Outer Diameter
      37.49 mm (1.4759 in.)

      If the outer diameter is less than the minimum, replace the inner 5th gear bearing race.

    2. A001TC6

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

      Standard Inside Diameter
      31.705 to 31.720 mm (1.2482 to 1.2488 in.)
      Maximum Inside Diameter
      31.720 mm (1.2488 in.)

      If the inside diameter exceeds the maximum, replace the inner 5th gear bearing race.

  12. INSPECT 6TH GEAR SUB-ASSEMBLY


    1. A001UFF

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

      Standard Inside Diameter
      40.109 to 40.125 mm (1.5790 to 1.5797 in.)
      Maximum Inside Diameter
      40.125 mm (1.5797 in.)

      If the inside diameter exceeds the maximum, replace the 6th gear sub-assembly.

  13. INSPECT 5TH GEAR


    1. A001WJL

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

      Standard Inside Diameter
      42.509 to 42.525 mm (1.6735 to 1.6742 in.)
      Maximum Inside Diameter
      42.525 mm (1.6742 in.)

      If the inside diameter exceeds the maximum, replace the 5th gear.

  14. INSPECT 4TH GEAR


    1. A001SR2

      Using a cylinder gauge, measure the inside diameter of the 4th gear.

      Standard Inside Diameter
      42.509 to 42.525 mm (1.6735 to 1.6742 in.)
      Maximum Inside Diameter
      42.525 mm (1.6742 in.)

      If the inside diameter exceeds the maximum, replace the 4th gear.

  15. INSPECT 3RD GEAR


    1. A001UVC

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

      Standard Inside Diameter
      42.509 to 42.525 mm (1.6735 to 1.6742 in.)
      Maximum Inside Diameter
      42.525 mm (1.6742 in.)

      If the inside diameter exceeds the maximum, replace the 3rd gear.

  16. INSPECT NO. 5 SYNCHRONIZER RING


    1. A001XBOC02
      *a Locks

      Check for wear and damage.

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

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

    4. Turn the synchronizer ring in one direction while pushing it against the 6th gear cone.

    5. Check that the ring locks.

      If the synchronizer ring does not lock, replace the synchronizer ring.

    6. Turn the synchronizer ring in one direction while pushing it against the 5th gear cone.

    7. Check that the ring locks.

      If the synchronizer ring does not lock, replace the synchronizer ring.

    8. A001Y7Z

      Using a feeler gauge, measure the clearance between the synchronizer ring and the gear spline end.

      Standard Clearance
      0.73 to 1.53 mm (0.0287 to 0.0602 in.)
      Minimum Clearance
      0.73 mm (0.0287 in.)

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

  17. INSPECT OUTER 2ND SYNCHRONIZER RING


    1. A001Y7AC02
      *a Locks

      Check for wear and damage.

    2. Coat the 4th gear cone with gear oil.

    3. Turn the synchronizer ring in one direction while pushing it against the 4th gear cone.

    4. Check that the ring locks.

      If the synchronizer ring does not lock, replace the synchronizer ring.

    5. A001WIP

      Using a feeler gauge, measure the clearance between the synchronizer ring and the gear spline end.

      Standard Clearance
      0.78 to 1.58 mm (0.0307 to 0.0622 in.)
      Minimum Clearance
      0.78 mm (0.0307 in.)

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

  18. INSPECT NO. 3 SYNCHRONIZER RING


    1. A001XDHC02
      *a Locks

      Check for wear and damage.

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

    3. Turn the synchronizer ring in one direction while pushing it against the 3rd gear cone.

    4. Check that the ring locks.

      If the synchronizer ring does not lock, replace the synchronizer ring.

    5. A001TDQ

      Using a feeler gauge, measure the clearance between the synchronizer ring and the gear spline end.

      Standard Clearance
      0.78 to 1.58 mm (0.0307 to 0.0622 in.)
      Minimum Clearance
      0.78 mm (0.0307 in.)

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

  19. INSPECT NO. 2 TRANSMISSION HUB SLEEVE


    1. A001VLY

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

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

    3. A001Y23C02
      *a Clearance

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

      Standard Clearance (A - B)
      0.1 to 0.5 mm (0.00394 to 0.0197 in.)

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

  20. INSPECT NO. 3 TRANSMISSION HUB SLEEVE


    1. A001VI1

      Check the sliding condition between the No. 3 transmission hub sleeve and the No. 3 transmission clutch hub.

    2. Check that the edges of the No. 3 transmission hub sleeve splines are not worn down.

    3. A001SIDC02
      *a Clearance

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

      Standard Clearance (A - B)
      0.1 to 0.5 mm (0.00394 to 0.0197 in.)

      If the clearance is out of specification, replace the No. 3 transmission hub sleeve and No. 3 gear shift fork.