Output Shaft Inspection

Using a feeler gauge, measure the 1st gear thrust clearance.

Standard clearance:

0.25 to 0.40 mm (0.00984 to 0.0157 in.)

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

Standard clearance:

0.10 to 0.35 mm (0.00394 to 0.0138 in.)

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

Standard Clearance:

Bearing	Standard Clearance mm (in.)
KOYO made	0.009 to 0.053 (0.000354 to 0.00209)
NSK made	0.009 to 0.051 (0.000354 to 0.00201)

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

Standard Clearance:

Bearing	Standard Clearance mm (in.)
KOYO made	0.009 to 0.053 (0.000354 to 0.00209)
NSK made	0.009 to 0.051 (0.000354 to 0.00201)

Using V-blocks and a dial indicator, inspect the shaft for runout.

Maximum runout:

0.03 mm (0.00118 in.)

Using a micrometer, measure the outside diameter of the output shaft journal surface.

Outside Diameter:

Part	Standard Outside Diameter mm (in.)	Minimum Outside Diameter mm (in.)
A	37.610 to 37.626 (1.4807 to 1.4813)	37.610 (1.4807)
B	34.502 to 34.512 (1.3583 to 1.3587)	34.502 (1.3583)

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

Inside Diameter:

Standard Inside Diameter mm (in.)	Maximum Inside Diameter mm (in.)
50.009 to 50.025 (1.9689 to 1.9695)	50.025 (1.9695)

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

Inside Diameter:

Standard Inside Diameter mm (in.)	Maximum Inside Diameter mm (in.)
51.009 to 51.025 (2.0082 to 2.0089)	51.025 (2.0089)

Coat the 2nd gear cone with gear oil.

Check for wear and damage.

Turn the synchronizer ring set in one direction while pushing it against the 2nd gear cone.

Check that the ring locks.
If the synchronizer ring set does not lock, replace the synchronizer ring set.

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

Standard clearance:

0.70 to 1.45 mm (0.0276 to 0.0571 in.)

Coat the 1st gear cone with gear oil.

Check for wear and damage.

Turn the synchronizer ring set in one direction while pushing it against the 1st gear cone.

Check that the ring set locks.
If the synchronizer ring set does not lock, replace the synchronizer ring set.

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

Standard clearance:

0.70 to 1.45 mm (0.0276 to 0.0571 in.)

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

Standard clearance:

0.15 to 0.35 mm (0.00591 to 0.0138 in.) {A - B}

Check the sliding condition between the No. 1 transmission clutch hub and the reverse gear.

Check the tip of the spline gear on the sleeve of the reverse gear for wear.
If any defects are found, replace the transmission hub sleeve or the transmission clutch hub.