INSPECT INPUT SHAFT

INSPECT 6TH GEAR

INSPECT 3RD GEAR

INSPECT 4TH GEAR

INSPECT NO. 2 TRANSMISSION HUB SLEEVE

INSPECT NO. 3 TRANSMISSION HUB SLEEVE

INSPECT NO. 3 SYNCHRONIZER RING (for 6th Gear)

INSPECT NO. 2 SYNCHRONIZER RING SET

INSPECT NO. 3 SYNCHRONIZER RING (for 4th Gear)

INSPECT 3RD GEAR THRUST WASHER

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 input shaft.

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)

If the outer diameter is less than the minimum, replace the input shaft.

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.)

If the inside diameter exceeds the maximum, replace the 6th gear.

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.)

If the inside diameter exceeds the maximum, replace the 3rd gear.

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.)

If the inside diameter exceeds the maximum, replace the 4th gear.

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.)

If the clearance is outside the specification, replace the No. 2 transmission hub sleeve and gear shift fork.

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.)

If the clearance is outside the specification, replace the No. 3 transmission hub sleeve and gear shift fork.

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.)

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

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.)

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

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.)

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

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.)

If the thickness is less than the minimum, replace the thrust washer.