Output Shaft Inspection

Check the No. 1 output shaft for wear and damage.

Using a dial indicator, check the No. 1 output shaft runout.

Maximum runout:

0.03 mm (0.0012 in.)

Using a micrometer, measure the diameter of the No. 1 output shaft journal surface.

Standard diameter:

Measured Part	Specified Condition
A	32.002 to 32.018 mm (1.2599 to 1.2605 in.)
B	35.084 to 36.000 mm (1.3813 to 1.4173 in.)
C	42.000 to 41.984 mm (1.6535 to 1.6529 in.)
D	42.000 to 41.989 mm (1.6535 to 1.6531 in.)
E	47.000 to 46.984 mm (1.8504 to 1.8498 in.)
F	36.002 to 36.018 mm (1.4174 to 1.4180 in.)

Using a dial indicator, measure the thrust clearance.

Standard thrust clearance:

0.10 to 0.35 mm (0.0039 to 0.0138 in.)

Maximum thrust clearance:

0.35 mm (0.0138 in.)

Using a dial indicator, measure the radial clearance.

Standard radial clearance:

0.015 to 0.068 mm (0.0006 to 0.0027 in.)

Maximum radial clearance:

0.068 mm (0.0027 in.)

Using a dial indicator, measure the thrust clearance.

Standard thrust clearance:

0.11 to 0.46 mm (0.0043 to 0.0181in.)

Maximum thrust clearance:

0.46 mm (0.0181 in.)

Using a dial indicator, measure the radial clearance.

Standard radial clearance:

0.015 to 0.048 mm (0.0006 to 0.0019 in.)

Maximum radial clearance:

0.048 mm (0.0019 in.)

Using a feeler gauge, measure the thrust clearance.

Standard thrust clearance:

0.11 to 0.54 mm (0.0043 to 0.0213 in.)

Maximum thrust clearance:

0.54 mm (0.0213 in.)

Using a dial indicator, measure the radial clearance.

Standard radial clearance:

0.015 to 0.066 mm (0.0006 to 0.0026 in.)

Maximum radial clearance:

0.066 mm (0.0026 in.)

Using a feeler gauge, measure the thrust clearance.

Standard thrust clearance:

0.10 to 0.65 mm (0.0039 to 0.0256 in.)

Maximum thrust clearance:

0.65 mm (0.0256 in.)

Using a dial indicator, measure the radial clearance.

Standard radial clearance:

0.015 to 0.066 mm (0.0006 to 0.0026 in.)

Maximum radial clearance:

0.066 mm (0.0026 in.)

Using a feeler gauge, measure the thrust clearance.

Standard thrust clearance:

0.10 to 0.55 mm (0.0039 to 0.0217 in.)

Maximum thrust clearance:

0.55 mm (0.0217 in.)

Using a dial indicator, measure the radial clearance.

Standard radial clearance:

0.015 to 0.066 mm (0.0006 to 0.0026 in.)

Maximum radial clearance:

0.066 mm (0.0026 in.)

Using a feeler gauge, measure the thrust clearance.

Standard thrust clearance:

0.10 to 0.55 mm (0.0039 to 0.0217 in.)

Maximum thrust clearance:

0.55 mm (0.0217 in.)

Using a dial indicator, measure the radial clearance.

Standard radial clearance:

0.015 to 0.066 mm (0.0006 to 0.0026 in.)

Maximum radial clearance:

0.066 mm (0.0026 in.)

Using a feeler gauge, measure the thrust clearance.

Standard thrust clearance:

0.11 to 0.34 mm (0.0043 to 0.0134 in.)

Maximum thrust clearance:

0.34 mm (0.0134 in.)

Using a dial indicator, measure the radial clearance.

Standard radial clearance:

0.015 to 0.068 mm (0.0006 to 0.0027 in.)

Maximum radial clearance:

0.068 mm (0.0027 in.)

Using a micrometer, measure the shaft diameter.

Standard diameter:

13.982 to 14.00 mm (0.5505 to 0.5512 in.)

Minimum diameter:

13.982 mm (0.5505 in.)

Using a micrometer, measure the shaft diameter.

Standard diameter:

13.982 to 14.00 mm (0.5505 to 0.5512 in.)

Minimum diameter:

13.982 mm (0.5505 in.)

Using a micrometer, measure the shaft diameter.

Standard diameter:

13.982 to 14.00 mm (0.5505 to 0.5512 in.)

Minimum diameter:

13.982 mm (0.5505 in.)

Using a micrometer, measure the shaft diameter.

Standard diameter:

13.982 to 14.00 mm (0.5505 to 0.5512 in.)

Minimum diameter:

13.982 mm (0.5505 in.)

Using a micrometer, measure the shaft diameter.

Standard diameter:

15.966 to 15.984 mm (0.6289 to 0.6293 in.)

Minimum diameter:

15.966 mm (0.6289 in.)

Using vernier calipers, measure the thickness and inside diameter.

Standard inside diameter and thickness:

A:

9.50 to 9.80 mm (0.3740 to 0.3858 in.)

B:

14.010 to 14.043 mm (0.5516 to 0.5529 in.)

Using vernier calipers, measure the thickness and inside diameter.

Standard inside diameter and thickness:

A:

9.50 to 9.80 mm (0.3740 to 0.3858 in.)

B:

14.010 to 14.043 mm (0.5516 to 0.5529 in.)

C:

14.70 to 15.30 mm (0.5787 to 0.6024 in.)

Using vernier calipers, measure the thickness and inside diameter.

Standard inside diameter and thickness:

A:

9.50 to 9.80 mm (0.3740 to 0.3858 in.)

B:

14.010 to 14.043 mm (0.5516 to 0.5529 in.)

Using vernier calipers, measure the thickness and inside diameter.

Standard inside diameter and thickness:

A:

4.40 to 4.56 mm (0.1732 to 0.1795 in.)

B:

14.010 to 14.043 mm (0.5516 to 0.5529 in.)

C:

14.7 to 15.3 mm (0.5787 to 0.6024 in.)

Using vernier calipers, measure the inside diameter.

Standard inside diameter:

13.994 to 14.054 mm (0.5509 to 0.5533 in.)

Maximum inside diameter:

13.994 to 14.054 mm (0.5509 to 0.5533 in.)

Using vernier calipers, measure the inside diameter.

Standard inside diameter:

A:

15.994 to 16.054 mm (0.6297 to 0.6320 in.)

B:

14.20 to 14.25 mm (0.5591 to 0.5610 in.)

Maximum inside diameter:

A:

15.994 to 16.054 mm (0.6297 to 0.6320 in.)

B:

14.20 to 14.25 mm (0.5591 to 0.5610 in.)

Using a cylinder gauge, measure the inside diameter.

Standard inside diameter:

53.015 to 53.040 mm (2.0872 to 2.0882 in.)

Maximum inside diameter:

53.040 mm (2.0882 in.)

Using a cylinder gauge, measure the inside diameter.

Standard inside diameter:

56.015 to 56.030 mm (2.0872 to 2.0878 in.)

Maximum inside diameter:

56.030 mm (2.0878 in.)

Using a cylinder gauge, measure the inside diameter.

Standard inside diameter:

42.015 to 42.040 mm (1.6541 to 1.6551 in.)

Maximum inside diameter:

42.040 mm (1.6551 in.)

Using a cylinder gauge, measure the inside diameter.

Standard inside diameter:

48.015 to 48.040 mm (1.8904 to 1.8913 in.)

Maximum inside diameter:

48.040 mm (1.8913 in.)

Coat the 1st driven gear with gear oil.

Check that the synchronizer ring does not turn when the ring is pushed to the 1st driven gear.

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

Standard clearance:

0.98 to 1.82 mm (0.0386 to 0.0716 in.)

Minimum clearance:

0.98 mm (0.0386 in.)

Coat the 2nd driven gear with gear oil.

Check that the synchronizer ring does not turn when the ring is pushed to the 2nd driven gear.

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

Standard clearance:

1.08 to 1.92 mm (0.0425 to 0.0756 in.)

Minimum clearance:

1.08 mm (0.0425 in.)

Coat the 3rd driven gear with gear oil.

Check that the synchronizer ring does not turn when the ring is pushed to the 3rd driven gear.

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

Standard clearance:

1.00 to 2.00 mm (0.0394 to 0.0787 in.)

Minimum clearance:

1.00 mm (0.0394 in.)

Coat the 4th driven gear with gear oil.

Check that the synchronizer ring does not turn when the ring is pushed to the 4th driven gear.

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

Standard clearance:

0.92 to 1.88 mm (0.0362 to 0.074 in.)

Minimum clearance:

0.92 mm (0.0362 in.)

Using a vernier caliper, measure the clearance between the No. 1 transmission hub sleeve and the No. 1 gear shift fork.

Standard clearance (A - B):

0.10 to 0.50 mm (0.0039 to 0.0197 in.)

Using a vernier caliper, measure the clearance between the No. 2 transmission hub sleeve and the No. 2 gear shift fork.

Standard clearance (A - B):

0.10 to 0.50 mm (0.0039 to 0.0197 in.)

Using a dial indicator, measure the output shaft runout.

Maximum runout:

0.03 mm (0.0012 in.)

Using a micrometer, measure the outer diameter of the No. 2 output shaft journal surface.

Standard diameter:

Measured Part	Specified Condition
A	32.002 to 32.018 mm (1.2599 to 1.2605 in.)
B	35.984 to 36.000 mm (1.4167 to 1.4173 in.)
C	41.984 to 42.000 mm (1.6529 to 1.6535 in.)
D	46.984 to 47.000 mm (1.8498 to 1.8504 in.)
E	35.002 to 35.018 mm (1.3780 to 1.3787 in.)

Using a cylinder gauge, measure the inside diameter.

Standard inside diameter:

48.015 to 48.040 mm (1.8904 to 1.8913 in.)

Maximum inside diameter:

48.040 mm (1.8913 in.)

Using a cylinder gauge, measure the inside diameter.

Standard inside diameter:

42.015 to 42.040 mm (1.6541 to 1.6551 in.)

Maximum inside diameter:

42.040 mm (1.6551 in.)

Using a cylinder gauge, measure the inside diameter.

Standard inside diameter:

53.015 to 53.040 mm (2.0872 to 2.0882 in.)

Maximum inside diameter:

53.040 mm (2.0882 in.)

Coat the 5th driven gear with gear oil.

Check that the synchronizer ring does not turn when the ring is pushed to the 5th driven gear.

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

Standard clearance:

0.80 to 1.60 mm (0.0315 to 0.063 in.)

Minimum clearance:

0.80 mm (0.0315 in.)

Coat the 6th driven gear with gear oil.

Check that the synchronizer ring does not turn when the ring is pushed to the 6th driven gear.

Using a feeler gauge, measure the clearance between the gear synchronizer ring back and the 6th driven gear spline end.

Standard clearance:

0.80 to 1.60 mm (0.0315 to 0.063 in.)

Minimum clearance:

0.80 mm (0.0315 in.)

Coat the reverse driven gear with gear oil.

Check that the synchronizer ring does not turn when the ring is pushed to the reverse driven gear.

Using a feeler gauge, measure the clearance between the synchronizer ring back and the reverse driven gear spline end.

Standard clearance:

0.68 to 1.32 mm (0.0268 to 0.052 in.)

Minimum clearance:

0.68 mm (0.0268 in.)

Using a vernier caliper, measure the clearance between the No. 3 transmission hub sleeve and the No. 3 gear shift fork.

Standard clearance (A - B):

0.10 to 0.50 mm (0.0039 to 0.0197 in.)

Using a vernier calipers, measure the clearance between the No. 4 transmission hub sleeve and the reverse shift fork.

Standard clearance (A - B):

0.15 to 0.41 mm (0.0059 to 0.0161 in.)