INPUT SHAFT INSPECTION

PROCEDURE

  1. INSPECT 6TH GEAR THRUST CLEARANCE

    1. C194221

      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. C194226

      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. C194227

      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. C194228

      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. C194222

      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. A295381

      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. C194224

      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 0.00197 in.)

      Maximum Clearance

      0.050 mm (0.00197 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. A295382

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

      Standard Clearance

      0.009 to 0.050 mm (0.000354 to 0.00197 in.)

      Maximum Clearance

      0.050 mm (0.00197 in.)

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

  9. INSPECT INPUT SHAFT

    1. C194251

      Using a dial indicator, check the input shaft runout.

      Maximum Runout

      0.015 mm (0.000591 in.)

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

    2. C194252N09

      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 (1.4757 to 1.4763 in.)

      Part C

      31.690 to 31.700 mm (1.2476 to 1.2480 in.)

      Part D

      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

      31.690 mm (1.2476 in.)

      Part D

      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. C194375

      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. C194377

      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. C194374

      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. C194376

      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. C194253

      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. C194254

      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. C194255

      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. C194256

      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. C204180C02

      *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 No. 5 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 No. 5 synchronizer ring.

    8. C194260

      Using a feeler gauge, measure the clearance between the No. 5 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 No. 5 synchronizer ring.

  17. INSPECT OUTER 2ND SYNCHRONIZER RING

    1. C204834C02

      *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 outer 2nd synchronizer ring does not lock, replace the outer 2nd synchronizer ring.

    5. C194261

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

  18. INSPECT NO. 3 SYNCHRONIZER RING

    1. C204835C02

      *a

      Locks

      Check for wear and damage.

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

    3. Turn the No. 3 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. C194262

      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 No. 3 synchronizer ring.

  19. INSPECT NO. 2 TRANSMISSION HUB SLEEVE

    1. C194263

      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. C194265C02

      *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. C194264

      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. C194266C02

      *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.