MULTI-MODE MANUAL TRANSAXLE UNIT INSPECTION

PROCEDURE

  1. INSPECT REVERSE IDLER GEAR SUB-ASSEMBLY

    1. G020995C01

      *1

      Reverse Idler Gear Shaft

      *2

      Reverse Idler Gear Sub-assembly

      Using a micrometer, inspect the reverse idler gear shaft.

      Standard Outer Diameter

      15.97 to 15.98 mm (0.62874 to 0.62913 in.)

      Minimum Outer Diameter

      15.97 mm (0.62874 in.)

      If the outer diameter is less than the minimum, replace the reverse idler gear shaft.

    2. Using a caliper gauge, inspect the reverse idler gear sub-assembly.

      Standard Inside Diameter

      16.04 to 16.05 mm (0.63150 to 0.63188 in.)

      Maximum Inside Diameter

      16.05 mm (0.63188 in.)

      If the inside diameter is more than the maximum, replace the reverse idler gear sub-assembly.

  2. INSPECT REVERSE SHIFT FORK

    1. G020996N06

      Using a caliper gauge, inspect the reverse shift fork.

      Standard Inside Diameter

      (A)

      14.27 to 14.42 mm (0.562 to 0.567 in.)

      (B)

      14.01 to 14.03 mm (0.55158 to 0.55236 in.)

      Maximum Inside Diameter

      (A)

      14.42 mm (0.567 in.)

      (B)

      14.03 mm (0.55236 in.)

      If the inside diameter is more than the maximum, replace the reverse shift fork.

  3. INSPECT NO. 1 GEAR SHIFT FORK SHAFT

    1. G021117

      Using a micrometer, inspect the No. 1 gear shift fork shaft.

      Standard Outer Diameter

      13.97 to 13.98 mm (0.55000 to 0.55039 in.)

      Minimum Outer Diameter

      13.97 mm (0.55000 in.)

      If the outer diameter is less than the minimum, replace the No. 1 gear shift fork shaft.

  4. INSPECT NO. 2 GEAR SHIFT FORK SHAFT

    1. G021118

      Using a micrometer, inspect the No. 2 gear shift fork shaft.

      Standard Outer Diameter

      13.97 to 13.98 mm (0.55000 to 0.55039 in.)

      Minimum Outer Diameter

      13.97 mm (0.55000 in.)

      If the outer diameter is less than the minimum, replace the No. 2 gear shift fork shaft.

  5. INSPECT NO. 3 GEAR SHIFT FORK SHAFT

    1. G021119

      Using a micrometer, inspect the No. 3 gear shift fork shaft.

      Standard Outer Diameter

      13.97 to 13.98 mm (0.55000 to 0.55039 in.)

      Minimum Outer Diameter

      13.97 mm (0.55000 in.)

      If the outer diameter is less than the minimum, replace the No. 3 gear shift fork shaft.

  6. INSPECT NO. 1 GEAR SHIFT FORK

    1. G021120N01

      Using a vernier caliper, inspect the No. 1 gear shift fork.

      Standard Inside Diameter and Thickness

      (A)

      9.9 to 10.0 mm (0.390 to 0.393 in.)

      (B)

      9.9 to 10.0 mm (0.390 to 0.393 in.)

      (C)

      14.00 to 14.02 mm (0.55118 to 0.55196 in.)

      If the inside diameter and thickness are not as specified, replace the No. 1 gear shift fork.

  7. INSPECT NO. 2 GEAR SHIFT FORK

    1. G021121N01

      Using a vernier caliper, inspect the No. 2 gear shift fork.

      Standard Inside Diameter and Thickness

      (A)

      9.9 to 10.0 mm (0.390 to 0.394 in.)

      (B)

      14.00 to 14.02 mm (0.55118 to 0.55196 in.)

      If the inside diameter and thickness are not as specified, replace the No. 2 gear shift fork.

  8. INSPECT NO. 3 GEAR SHIFT FORK

    1. G021122N01

      Using a vernier caliper, inspect the No. 3 gear shift fork.

      Standard Inside Diameter and Thickness

      (A)

      9.9 to 10.0 mm (0.390 to 0.394 in.)

      (B)

      14.00 to 14.02 mm (0.55118 to 0.55196 in.)

      If the inside diameter and thickness are not as specified, replace the No. 3 gear shift fork.

  9. INSPECT NO. 1 GEAR SHIFT HEAD

    1. G021123

      Using a vernier caliper, inspect the No. 1 gear shift head.

      Standard Inside Diameter

      14.00 to 14.05 mm (0.552 to 0.553 in.)

      Maximum Inside Diameter

      14.05 mm (0.553 in.)

      If the inside diameter is more than the maximum, replace the No. 1 gear shift head.

  10. INSPECT NO. 3 GEAR SHIFT HEAD

    1. G021124N01

      Using a vernier caliper, inspect the No. 3 gear shift head.

      Standard Inside Diameter

      (A)

      14.00 to 14.05 mm (0.552 to 0.553 in.)

      (B)

      14.2 to 14.4 mm (0.560 to 0.566 in.)

      Maximum Inside Diameter

      (A)

      14.05 mm (0.553 in.)

      (B)

      14.4 mm (0.566 in.)

      If the inside diameter is more than the maximum, replace the No. 3 gear shift head.