OUTPUT SHAFT INSPECTION

PROCEDURE

  1. INSPECT 1ST GEAR THRUST CLEARANCE

    1. G021392

      Using a feeler gauge, measure the 1st 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. 1 transmission clutch hub, 1st gear or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  2. INSPECT 2ND GEAR THRUST CLEARANCE

    1. G021393

      Using a feeler gauge, measure the 2nd 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 2nd gear, No. 1 transmission clutch hub, 3rd driven gear or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  3. INSPECT 1ST GEAR RADIAL CLEARANCE

    1. G021394

      Using a dial indicator, measure the 1st gear radial clearance.

      Standard Clearance

      0.015 to 0.056 mm (0.000591 to 0.00220 in.)

      Maximum Clearance

      0.056 mm (0.00220 in.)

      If the clearance is more than the maximum, replace the 1st gear needle roller bearing, 1st gear or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  4. INSPECT 2ND GEAR RADIAL CLEARANCE

    1. G021395

      Using a dial indicator, measure the 2nd gear radial clearance.

      Standard Clearance

      0.015 to 0.056 mm (0.000591 to 0.00220 in.)

      Maximum Clearance

      0.056 mm (0.00220 in.)

      If the clearance is more than the maximum, replace the 2nd gear needle roller bearing, 2nd gear or output shaft. Replace the part or parts determined to be the most likely cause of the problem.

  5. INSPECT OUTPUT SHAFT

    1. G021370

      Using a dial indicator, measure the output shaft runout.

      Maximum Runout

      0.03 mm (0.00118 in.)

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

    2. G102226N01

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

      Standard Outer Diameter

      Part (A)

      23.002 to 23.015 mm (0.90559 to 0.90610 in.)

      Part (B) and (C)

      28.3 mm (1.11 in.)

      Part (D) and (E)

      33.985 to 34.000 mm (1.33799 to 1.33858 in.)

      Part (F)

      25.002 to 25.015 mm (0.98433 to 0.98484 in.)

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

  6. INSPECT 1ST GEAR

    1. G021372

      Using a cylinder gauge, measure the inside diameter of the 1st 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 1st gear.

  7. INSPECT 2ND GEAR

    1. G021373

      Using a cylinder gauge, measure the inside diameter of the 2nd 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 2nd gear.

  8. INSPECT 1ST GEAR SYNCHRONIZER RING

    1. G021366

      Check for wear and damage.

    2. Coat the 1st gear cone with gear oil.

    3. Turn the 1st gear synchronizer ring in both directions while pushing it against the 1st gear cone and check that it locks in both directions.

      If the 1st gear synchronizer ring does not lock, replace the 1st gear synchronizer ring.

    4. G021367

      Using a feeler gauge, measure the clearance between the 1st gear synchronizer ring and 1st 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 1st gear synchronizer ring.

  9. INSPECT 2ND GEAR SYNCHRONIZER RING

    1. G021368

      Check for wear and damage.

    2. Coat the 2nd gear cone with gear oil.

    3. Turn the 2nd gear synchronizer ring in both directions while pushing it against the 2nd gear cone and check that it locks in both directions.

      If the 2nd gear synchronizer ring does not lock, replace the 2nd gear synchronizer ring.

    4. G021369

      Using a feeler gauge, measure the clearance between the 2nd gear synchronizer ring and 2nd 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 2nd gear synchronizer ring.

  10. INSPECT REVERSE GEAR

    1. G021365N01

      Using a vernier caliper, measure the width of the reverse gear groove (A) and thickness of the claw part on the No. 1 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. 1 gear shift fork and reverse gear.