Input Shaft Inspection

Using a dial indicator, measure the 6th gear thrust clearance.

Standard clearance:

0.20 to 0.47 mm (0.00787 to 0.0185 in.)

Maximum clearance:

0.47 mm (0.0185 in.)

Using a dial indicator, measure the 5th gear thrust clearance.

Standard clearance:

0.20 to 0.47 mm (0.00787 to 0.0185 in.)

Maximum clearance:

0.47 mm (0.0185 in.)

Using a dial indicator, measure the 4th gear thrust clearance.

Standard clearance:

0.13 to 0.60 mm (0.00512 to 0.0236 in.)

Maximum clearance:

0.60 mm (0.0236 in.)

Using a dial indicator, measure the 3rd gear thrust clearance.

Standard clearance:

0.20 to 0.47 mm (0.00787 to 0.0185 in.)

Maximum clearance:

0.47 mm (0.0185 in.)

Using a dial indicator, measure the 6th gear radial clearance between the gear and shaft.

Standard clearance:

0.009 to 0.045 mm (0.000355 to 0.00177 in.)

Maximum clearance:

0.045 mm (0.00177 in.)

Using a dial indicator, measure the 5th gear radial clearance between the gear and shaft.

Standard clearance:

0.009 to 0.045 mm (0.000355 to 0.00177 in.)

Maximum clearance:

0.045 mm (0.00177 in.)

Using a dial indicator, measure the 4th gear radial clearance between the gear and shaft.

Standard clearance:

0.009 to 0.036 mm (0.000355 to 0.00142 in.)

Maximum clearance:

0.036 mm (0.00142 in.)

Using a dial indicator, measure the 3rd gear radial clearance.

Standard clearance:

0.009 to 0.047 mm (0.0003554 to 0.00185 in.)

Maximum clearance:

0.047 mm (0.00185 in.)

Using a dial indicator, measure the input shaft runout.

Maximum runout:

0.03 mm (0.00118 in.)

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

Standard outer diameter:

Journal A:

27.608 to 27.620 mm (1.0869 to 1.0873 in.)

Journal B:

41.290 to 41.300 mm (1.6255 to 1.6259 in.)

Journal C:

38.280 to 38.300 mm (1.5070 to 1.5078 in.)

Journal D:

35.490 to 35.500 mm (1.3972 to 1.3976 in.)

Minimum outer diameter:

Journal A:

27.608 mm (1.0869 in.)

Journal B:

41.290 mm (1.6255 in.)

Journal C:

38.280 mm (1.5070 in.)

Journal D:

35.490 mm (1.3972 in.)

Using a micrometer, measure the outer diameter of the inner 6th gear bearing race.

Standard outer diameter:

42.29 to 42.30 mm (1.6649 to 1.6653 in.)

Minimum outer diameter:

42.29 mm (1.6649 in.)

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

Standard inside diameter:

35.500 to 35.515 mm (1.3976 to 1.3982 in.)

Maximum inside diameter:

35.515 mm (1.3982 in.)

Using a micrometer, measure the outer diameter of the inner 5th gear bearing race.

Standard outer diameter:

45.29 to 45.30 mm (1.7830 to 1.7834 in.)

Minimum outer diameter:

45.29 mm (1.7830 in.)

Using a cylinder gauge, measure the inside diameter of the inner 5th gear bearing race.

Standard inside diameter:

38.300 to 38.315 mm (1.5078 to 1.5084 in.)

Maximum inside diameter:

38.315 mm (1.5084 in.)

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

Standard inside diameter:

47.309 to 47.325 mm (1.8625 to 1.8631 in.)

Maximum inside diameter:

47.325 mm (1.8631 in.)

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

Standard inside diameter:

50.309 to 50.325 mm (1.9806 to 1.9812 in.)

Maximum inside diameter:

50.325 mm (1.9806 in.)

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

Standard inside diameter:

47.301 to 47.317 mm (1.8622 to 1.8628 in.)

Maximum inside diameter:

47.317 mm (1.8628 in.)

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

Standard inside diameter:

47.309 to 47.325 mm (1.8625 to 1.8631 in.)

Maximum inside diameter:

47.325 mm (1.8631 in.)

Check for wear and damage.

Coat the 6th gear cone with gear oil.

Coat the 5th gear cone with gear oil.

Turn the synchronizer ring in both directions while pushing it against the 6th gear cone and check that it locks in both directions.
If the synchronizer ring does not lock, replace the synchronizer ring.

Turn the synchronizer ring in both directions while pushing it against the 5th gear cone and check that it locks in both directions.
If the synchronizer ring does not lock, replace the synchronizer ring.

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

Standard clearance:

0.88 to 1.52 mm (0.0346 to 0.0598 in.)

Minimum clearance:

0.88 mm (0.0346 in.)

Check for wear and damage.

Coat the 4th gear cone with gear oil.

Turn the synchronizer ring in both directions while pushing it against the 4th gear cone and check that it locks in both directions.
If the synchronizer ring does not lock, replace the synchronizer ring.

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

Standard clearance:

0.88 to 1.72 mm (0.0346 to 0.0677 in.)

Minimum clearance:

0.88 mm (0.0346 in.)

Check for wear and damage.

Coat the 3rd gear cone with gear oil.

Turn the synchronizer ring in both directions while pushing it against the 3rd gear cone and check that it locks in both directions.
If the synchronizer ring does not lock, replace the synchronizer ring.

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

Standard clearance:

0.78 to 1.62 mm (0.0307 to 0.0637 in.)

Minimum clearance:

0.78 mm (0.0307 in.)

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

Check that the edges of the No. 2 transmission hub sleeve spline gear are not worn down.

Using a vernier caliper, 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 fork (B), and calculate the clearance.

Standard clearance (A - B):

0.1 to 0.5 mm (0.00394 to 0.0197 in.)

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

Check that the edges of the No. 3 transmission hub sleeve spline gear are not worn down.

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

Standard clearance (A - B):

0.1 to 0.5 mm (0.00394 to 0.0197 in.)