INSPECT COUNTER GEAR

INSPECT COUNTER SHAFT REVERSE GEAR

INSPECT COUNTER SHAFT GEAR 1ST SPEED

INSPECT COUNTER SHAFT 2ND SPEED GEAR

INSPECT NO. 3 TRANSMISSION HUB SLEEVE

INSPECT NO. 1 TRANSMISSION HUB SLEEVE

INSPECT NO. 4 SYNCHRONIZER RING

INSPECT NO. 1 SYNCHRONIZER RING SET (for 1st Gear)

INSPECT NO. 1 SYNCHRONIZER RING SET (for 2nd Gear)

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

• Maximum runout:
• 0.03 mm (0.0012 in.)

If the runout exceeds the maximum, replace the counter gear.

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	36.985 to 37.000 (1.4561 to 1.4567)
  C	47.985 to 48.000 (1.8892 to 1.8898)
  D	53.985 to 54.000 (2.1254 to 2.1260)
  E	34.002 to 34.015 (1.3387 to 1.3392)

• Minimum:

• Part	Outer diameter mm (in.)
  A	34.002 (1.3387)
  B	36.985 (1.4561)
  C	47.985 (1.8892)
  D	53.985 (2.1254)
  E	34.002 (1.3387)

If the diameter is less than the minimum, replace the counter gear shaft.

Using a cylinder gauge, measure the inside diameter of the reverse 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.)

If the inside diameter exceeds the maximum, replace the reverse gear.

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

• Standard inside diameter:
• 54.015 to 54.040 mm (2.1266 to 2.1276 in.)

• Maximum inside diameter:
• 54.040 mm (2.1276 in.)

If the inside diameter exceeds the maximum, replace the 1st gear.

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

• Standard inside diameter:
• 60.015 to 60.040 mm (2.3628 to 2.3638 in.)

• Maximum inside diameter:
• 60.040 mm (2.3638 in.)

If the inside diameter exceeds the maximum, replace the 2nd gear.

Using vernier calipers, measure the width of the No. 3 transmission hub sleeve groove (A) and the thickness of the claw part on the No. 4 gear shift fork (B), and calculate the clearance.

• Standard clearance (A - B):
• 0.26 to 0.84 mm (0.0102 to 0.0331 in.)

If the clearance is not as specified, replace the No. 3 transmission hub sleeve and No. 4 gear shift fork.

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

Check that the spline gear teeth of the No. 1 transmission hub sleeve are not worn.

Using vernier calipers, measure the width of the No. 1 transmission hub sleeve groove (A) and the thickness of the claw part on the No. 1 gear shift fork (B), and calculate the clearance.

• Standard clearance (A - B):
• 0.15 to 0.35 mm (0.0059 to 0.0138 in.)

If the clearance is not as specified, replace the No. 1 transmission hub sleeve and the No. 1 gear shift fork.

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

• Standard clearance:
• 0.70 to 1.30 mm (0.0276 to 0.0512 in.)

• Minimum clearance:
• 0.70 mm (0.0276 in.)

If the clearance is less than the minimum, replace the synchronizer ring.

Coat the reverse 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 reverse gear cone. Check that the ring locks.

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

• Standard clearance:
• Inner:
• 1.48 to 2.12 mm (0.0583 to 0.0835 in.)
• Middle:
• 0.68 to 1.92 mm (0.0268 to 0.0756 in.)
• Outer:
• 0.88 to 1.72 mm (0.0346 to 0.0677 in.)

• Minimum clearance:
• Inner:
• 1.48 mm (0.0583 in.)
• Middle:
• 0.68 mm (0.0268 in.)
• Outer:
• 0.88 mm (0.0346 in.)

If the clearance is less than the minimum, replace the synchronizer ring.

Coat the 1st 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 1st gear cone. Check that the ring locks.

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

• Standard clearance:
• Inner:
• 1.48 to 2.12 mm (0.0583 to 0.0835 in.)
• Middle:
• 0.68 to 1.92 mm (0.0268 to 0.0756 in.)
• Outer:
• 0.88 to 1.72 mm (0.0346 to 0.0677 in.)

• Minimum clearance:
• Inner:
• 1.48 mm (0.0583 in.)
• Middle:
• 0.68 mm (0.0268 in.)
• Outer:
• 0.88 mm (0.0346 in.)

If the clearance is less than the minimum, replace the synchronizer ring.

Coat the 2nd 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 2nd gear cone. Check that the ring locks.