Input Shaft Inspection

Using a dial indicator and 2 V-blocks, measure the shaft runout.

Maximum runout:

0.03 mm (0.0012 in.)

Using a micrometer, measure the outer diameter of the input shaft journal surface.

Standard:

Part	Outer diameter mm (in.)
A	34.002 to 34.015 (1.3387 to 1.3392)
B	44.985 to 45.000 (1.7711 to 1.7717)
C	44.985 to 45.000 (1.7711 to 1.7717)
D	41.985 to 42.000 (1.6530 to 1.6535)
E	32.967 to 32.980 (1.2979 to 1.2984)

Minimum:

Part	Outer diameter mm (in.)
A	34.002 (1.3387)
B	44.985 (1.7711)
C	44.985 (1.7711)
D	41.985 (1.6530)
E	32.967 (1.2979)

Using a cylinder gauge, measure the inside diameter of the 6th gear.

Standard inside diameter:

51.015 to 51.040 mm (2.0085 to 2.0095 in.)

Maximum inside diameter:

51.040 mm (2.0095 in.)

Using a cylinder gauge, measure the inside diameter of the 3rd gear.

Standard inside diameter:

51.015 to 51.040 mm (2.0085 to 2.0095 in.)

Maximum inside diameter:

51.040 mm (2.0095 in.)

Using a cylinder gauge, measure the inside diameter of the 4th gear.

Standard inside diameter:

51.015 to 51.040 mm (2.0085 to 2.0095 in.)

Maximum inside diameter:

51.040 mm (2.0095 in.)

Check the sliding condition between the No. 2 transmission clutch hub and No. 2 transmission hub sleeve.

Check that the spline gear teeth of the No. 2 transmission hub sleeve are not worn.
If there are any defects, replace the No. 2 transmission hub sleeve.

Using vernier calipers, 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 forks (B), and calculate the clearance.

Standard clearance (A - B):

0.28 to 0.66 mm (0.0110 to 0.0260 in.)

Check the sliding condition between the No. 3 transmission clutch hub and No. 3 transmission hub sleeve.

Check that the spline gear teeth of the No. 3 transmission hub sleeve are not worn.
If there are any defects, replace the No. 3 transmission hub sleeve.

Using vernier calipers, measure the width of the No. 2 transmission hub sleeve groove (A) and the thickness of the claw part on the No. 3 and No. 3 gear shift forks (B), and calculate the clearance.

Standard clearance (A - B):

0.28 to 0.66 mm (0.0110 to 0.0260 in.)

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

Standard clearance:

0.80 to 1.60 mm (0.0315 to 0.0630 in.)

Minimum clearance:

0.80 mm (0.0315 in.)

Coat the 6th gear cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it onto the 6th gear cone. Check that the ring locks.

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

Standard clearance:

Inner:

1.20 to 2.20 mm (0.0472 to 0.0866 in.)

Middle:

0.60 to 1.80 mm (0.0236 to 0.0709 in.)

Outer:

0.80 to 1.80 mm (0.0315 to 0.0709 in.)

Minimum clearance:

Inner:

1.20 mm (0.0472 in.)

Middle:

0.60 mm (0.0236 in.)

Outer:

0.80 mm (0.0315 in.)

Coat the 3rd gear cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it onto the 3rd gear cone. Check that the ring locks.

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

Standard clearance:

0.80 to 1.60 mm (0.0315 to 0.0630 in.)

Minimum clearance:

0.80 mm (0.0315 in.)

Coat the 4th gear cone with gear oil. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it onto the 4th gear cone. Check that the ring locks.

Using a micrometer, measure the thrust washer thickness.

Standard thickness:

7.12 to 7.18 mm (0.2803 to 0.2827 in.)

Minimum thickness:

7.12 mm (0.2803 in.)