- Using a dial indicator, measure the thrust
clearance of 6th gear.
Thrust Clearance
Standard thrust clearance should be between 0.10-0.60 mm (0.0039-0.0236 in).
Maximum clearance should not exceed 0.60 mm (0.0236 in).
- Using a dial indicator, measure the radial
runout of 6th gear.
Thrust Clearance
Standard radial runout should be between 0.009-0.50 mm (0.0003-0.0020 in).
Maximum runout should not exceed 0.50 mm (0.0020 in).
- If the gear exceeds any of the maximum measurements, replace the gear,
roller bearing or shaft.
- Using a dial indicator, measure the thrust
clearance of 5th gear.
Thrust Clearance
Standard thrust clearance should be between 0.10-0.62 mm (0.0039-0.0244 in).
Maximum clearance should not exceed 0.62 mm (0.0244 in).
- Using a dial indicator, measure the radial
runout of 5th gear.
Thrust Clearance
Standard radial runout should be between 0.015-0.056 mm (0.0006-0.0022 in).
Maximum runout should not exceed 0.56 mm (0.0022 in).
- If the gear exceeds any of the maximum measurements, replace the gear,
roller bearing or shaft.
- Using a feeler gage, measure the thrust
clearance for 3rd and 4th gears of the input shaft.
Standard Clearance
3rd gear: 0.10-0.35 mm (0.0039-0.0138 in). 4th gear:
0.10-0.55 mm (0.0039-0.0217 in).
- Using a dial indicator, measure the radial
clearance between the gears and the shaft.
Standard Clearance
3rd and 4th gear radial clearance: 0.15-0.58 mm (0.0006-0.0023 in).
- If the clearance exceeds the maximum measurement, replace the gear, roller
bearing or shaft.
- Check the 3rd and 4th gear braking action
of the synchronizer ring. Turn the synchronizer ring in one direction while pushing
it into the gear cone. Ensure that the ring locks. Replace the ring if necessary.
- Using a feeler gage, measure the clearance
between the synchronizer ring and the gear spline end. 3rd gear minimum clearance
is 0.65 mm (0.0256 in). 4th gear minimum clearance is 0.75 mm
(0.0295 in). If the clearance is less than the minimum, replace the synchronizer
ring.
- Using a feeler gage, measure the clearance
between the hub sleeve and the gear shift fork. Maximum clearance is 0.35 mm
(0.014 in). If the clearance exceeds the maximum, replace the gear shift fork
or hub sleeve.
- Using a micrometer, measure the outer diameter
of the input shaft journal surfaces.
Minimum Outer Diameter
| • | A: 21.991 mm (0.8658 in) |
| • | B: 24.885 mm (0.9797 in) |
| • | C: 28.985 mm (1.1411 in) |
| • | D: 30.985 mm (1.2199 in) |
| • | E: 24.985 mm (0.9837 in) |
- If the out diameter is less than the minimum, replace the input shaft.
- Using a dial indicator, check the output
shaft journals for runout. Maximum runout is 0.03 mm (0.0012 in).
- If the runout exceeds the maximum, replace the output shaft.
- Using a feeler gage, measure the thrust
clearance for 1st and 2nd gears of the output shaft.
Standard Clearance
1st gear: 0.10-0.40 mm (0.0039-0.0157 in). 2nd gear:
0.10-0.55 mm (0.0039-0.0217 in).
- Using a dial indicator, measure the radial
clearance between the gears and the shaft.
Standard Clearance
1st and 2nd gear radial clearance: 0.15-0.58 mm (0.0006-0.0023 in).
- If the clearance exceeds the maximum measurement, replace the gear, roller
bearing or shaft.
- Check the 1st gear braking action of the
synchronizer ring. Turn the synchronizer ring in one direction while pushing it into
the gear cone. Ensure that the ring locks. Replace the ring if necessary.
- Using a feeler gage, measure the clearance
between the synchronizer ring and the gear spline end. Minimum clearance is 0.75 mm
(0.0295 in). If the clearance is less than the minimum, replace the synchronizer
ring.
- Check the 2nd gear braking action of the
synchronizer ring. Turn the synchronizer ring in one direction while pushing it into
the gear cone. Ensure that the ring locks. Replace the ring if necessary.
- Using a feeler gage, measure the clearance
between the synchronizer ring and the gear spline end. Minimum clearance is 0.70 mm
(0.0276 in). If the clearance is less than the minimum, replace the synchronizer
ring.
- Using a feeler gage, measure the clearance
between the hub sleeve and the gear shift fork. Maximum clearance is 0.35 mm
(0.014 in). If the clearance exceeds the maximum, replace the gear shift fork
or hub sleeve.
- Using a micrometer, measure the outer diameter
of the input shaft journal surfaces.
Minimum Outer Diameter
| • | 1: 31.985 mm (1.2592 in) |
| • | 2: 37.985 mm (1.4955 in) |
| • | 3: 32.985 mm (1.2986 in) |
- If the out diameter is less than the minimum, replace the output shaft.
- Using a dial indicator, check the output
shaft journals for runout. maximum runout is 0.03 mm (0.0012 in).
- If the runout exceeds the maximum, replace the output shaft.
