Manual Transmission Unit Inspection

Apply gear oil to the cone part of the No. 5 gear spline piece, and check that the No. 3 synchronizer ring does not turn in either direction while pushing it against the No. 5 gear spline piece.

1. If the No. 3 synchronizer ring turns, replace it.
   

Push the No. 3 synchronizer ring outer against the cone part of the No. 5 gear spline piece. Measure the clearance between the No. 3 synchronizer ring outer and No. 5 gear spline piece.

Standard clearance:

0.68 to 1.32 mm (0.0267 to 0.0519 in.)

1. If the clearance is not as specified, replace the outer No. 3 synchronizer ring with a new one.
   

Check the sliding condition between the counter shaft 5th gear and No. 3 transmission hub sleeve.

Check the spline of the No. 3 transmission hub sleeve for wear.

1. If there are any defects, replace the No. 3 transmission hub sleeve.
   

Using a vernier caliper, measure the No. 3 transmission hub sleeve groove and the thickness of the claw part of the No. 3 shift fork and calculate the clearance.

Standard clearance:

0.26 to 0.84 mm (0.0102 to 0.0331 in.)

1. If the clearance is not as specified, replace the No. 3 transmission hub sleeve and No. 3 shift fork with new ones.
   

Using a cylinder gauge, measure the inside diameter of the counter 5th gear.

Standard inside diameter:

38.015 to 38.040 mm (1.4967 to 1.4976 in.)

Maximum inside diameter:

38.040 mm (1.4976 in.)

1. If the inside diameter is more than the maximum, replace the counter shaft 5th gear with a new one.
   

Using a caliper gauge, measure the inside diameter of the reverse idler gear.

Standard inside diameter:

24.040 to 24.061 mm (0.9465 to 0.9473 in.)

Maximum inside diameter:

24.061 mm (0.9473 in.)

1. If the inside diameter is more than the maximum, replace the reverse idler gear with a new one.
   

Using a micrometer, measure the diameter of the reverse idler gear shaft where the reverse idler gear rotates.

Standard diameter:

23.979 to 24.000 mm (0.9441 to 0.9449 in.)

Minimum diameter:

23.979 mm (0.9441 in.)

1. If the diameter is less than the minimum, replace the reverse idler gear shaft.
   

Install the reverse idler gear to the reverse idler gear shaft, and clamp the shaft in a vise between aluminum plates.

Using a dial indicator, measure the radial clearance.

Standard clearance:

0.040 to 0.082 mm (0.00157 to 0.00322 in.)

1. If the clearance is not as specified, replace the reverse idler gear.