INPUT SHAFT INSPECTION

PROCEDURE

  1. INSPECT 3RD GEAR THRUST CLEARANCE

    1. G021219

      Using a feeler gauge, measure the 3rd gear thrust clearance.

      Standard Clearance

      0.10 to 0.35 mm (0.00394 to 0.0137 in.)

      Maximum Clearance

      0.35 mm (0.0137 in.)

      If the clearance is more than the maximum, replace the No. 2 transmission clutch hub, 3rd gear or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  2. INSPECT 5TH GEAR THRUST CLEARANCE

    1. G021220

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

      Standard Clearance

      0.10 to 0.50 mm (0.00394 to 0.0196 in.)

      Maximum Clearance

      0.50 mm (0.0196 in.)

      If the clearance is more than the maximum, replace the No. 3 transmission clutch hub, 5th gear or 5th gear thrust washer. Replace the part or parts determined to be the most likely cause of the problem.

  3. INSPECT 3RD GEAR RADIAL CLEARANCE

    1. G021221

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

      Standard Clearance

      0.015 to 0.058 mm (0.000591 to 0.00228 in.)

      Maximum Clearance

      0.058 mm (0.00228 in.)

      If the clearance is more than the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  4. INSPECT 4TH GEAR RADIAL CLEARANCE

    1. G021222

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

      Standard Clearance

      0.015 to 0.058 mm (0.000591 to 0.00228 in.)

      Maximum Clearance

      0.058 mm (0.00228 in.)

      If the clearance is more than the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  5. INSPECT 5TH GEAR RADIAL CLEARANCE

    1. G021223

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

      Standard Clearance

      0.015 to 0.058 mm (0.000591 to 0.00228 in.)

      Maximum Clearance

      0.058 mm (0.00228 in.)

      If the clearance is more than the maximum, replace the 5th gear, 5th gear needle roller bearing or input shaft. Replace the part or parts determined to be the most likely cause of the problem.

  6. INSPECT 4TH GEAR THRUST CLEARANCE

    1. G021228

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

      Standard Clearance

      0.10 to 0.55 mm (0.00394 to 0.0216 in.)

      Maximum Clearance

      0.55 mm (0.0216 in.)

      If the clearance is more than the maximum, replace the No. 2 transmission clutch hub, 4th gear or 5th gear thrust washer. Replace the part or parts determined to be the most likely cause of the problem.

  7. INSPECT INPUT SHAFT

    1. Check the input shaft for wear and damage.

    2. G021244

      Using a dial indicator, measure the input shaft runout.

      Maximum Runout

      0.03 mm (0.00118 in.)

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

    3. G102225N01

      Using a micrometer, measure the outer diameter of the input shaft journals at the locations indicated in the illustration.

      Standard Outer Diameter

      Part (A)

      25.502 to 25.515 mm (1.00401 to 1.00453 in.)

      Part (B)

      30.985 to 31.000 mm (1.21988 to 1.22047 in.)

      Part (C) and (D)

      33.985 to 34.000 mm (1.33799 to 1.33858 in.)

      Part (E)

      23.002 to 23.015 mm (0.90559 to 0.90610 in.)

      Part (F)

      22.967 to 23.000 mm (0.90421 to 0.90551 in.)

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

  8. INSPECT 3RD GEAR

    1. G021246

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

      Standard Inside Diameter

      39.015 to 39.031 mm (1.53602 to 1.53665 in.)

      Maximum Inside Diameter

      39.031 mm (1.53665 in.)

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

  9. INSPECT 4TH GEAR

    1. G021246

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

      Standard Inside Diameter

      39.015 to 39.031 mm (1.53602 to 1.53665 in.)

      Maximum Inside Diameter

      39.031 mm (1.53665 in.)

      If the inside diameter is more than the maximum, replace the 4th gear.

  10. INSPECT 5TH GEAR

    1. G021246

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

      Standard Inside Diameter

      36.015 to 36.031 mm (1.41791 to 1.41854 in.)

      Maximum Inside Diameter

      36.031 mm (1.41854 in.)

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

  11. INSPECT 3RD GEAR SYNCHRONIZER RING

    1. Check for wear and damage.

    2. G021238

      Coat the 3rd gear cone with gear oil.

    3. Turn the 3rd gear synchronizer ring in both directions while pushing it against the 3rd gear cone and check that it locks in both directions.

      If the 3rd gear synchronizer ring does not lock, replace the 3rd gear synchronizer ring.

    4. G021239

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

      Standard Clearance

      0.75 to 1.65 mm (0.0295 to 0.0650 in.)

      Minimum Clearance

      0.75 mm (0.0295 in.)

      If the clearance is less than the minimum, replace the 3rd gear synchronizer ring.

  12. INSPECT 4TH GEAR SYNCHRONIZER RING

    1. Check for wear and damage.

    2. G021238

      Coat the 4th gear cone with gear oil.

    3. Turn the 4th gear synchronizer ring in both directions while pushing it against the 4th gear cone and check that it locks in both directions.

      If the 4th gear synchronizer ring does not lock, replace the 4th gear synchronizer ring.

    4. G021239

      Using a feeler gauge, measure the clearance between the 4th gear synchronizer ring and 4th gear spline end.

      Standard Clearance

      0.75 to 1.65 mm (0.0295 to 0.0650 in.)

      Minimum Clearance

      0.75 mm (0.0295 in.)

      If the clearance is less than the minimum, replace the 4th gear synchronizer ring.

  13. INSPECT 5TH GEAR SYNCHRONIZER RING

    1. Check for wear and damage.

    2. G021238

      Coat the 5th gear cone with gear oil.

    3. Turn the 5th gear synchronizer ring in both directions while pushing it against the 5th gear cone and check that it locks in both directions.

      If the 5th gear synchronizer ring does not lock, replace the 5th gear synchronizer ring.

    4. G021239

      Using a feeler gauge, measure the clearance between the 5th gear synchronizer ring and 5th gear spline end.

      Standard Clearance

      0.75 to 1.65 mm (0.0295 to 0.0650 in.)

      Minimum Clearance

      0.75 mm (0.0295 in.)

      If the clearance is less than the minimum, replace the 5th gear synchronizer ring.

  14. INSPECT NO. 2 TRANSMISSION HUB SLEEVE

    1. G021241N04

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

      Standard Clearance (A - B)

      0.15 to 0.35 mm (0.00591 to 0.0137 in.)

      If the result is not as specified, replace the No. 2 transmission hub sleeve and No. 2 gear shift fork.

  15. INSPECT NO. 3 TRANSMISSION HUB SLEEVE

    1. G021243N03

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

      Standard Clearance (A - B)

      0.15 to 0.35 mm (0.00591 to 0.0137 in.)

      If the result is not as specified, replace the No. 3 transmission hub sleeve and No. 3 gear shift fork.