Output Shaft Inspection

Using a dial indicator, measure the output shaft runout.

Maximum runout:

0.03 mm (0.00118 in.)

1. If the runout is more than the maximum, replace the output shaft with a new one.
   

Using a micrometer, measure the journal diameter at A, B and C on the output shaft.

Standard Journal Diameter:

Item	Specified Condition
Journal A	38.979 to 38.995 mm (1.5346 to 1.5352 in.)
Journal B	46.984 to 47.000 mm (1.8498 to 1.8504 in.)
Journal C	37.984 to 38.000 mm (1.4954 to 1.4961 in.)

1. If the diameter is not as specified, replace the output shaft with a new one.
   

Using a micrometer, measure the thickness of the output shaft flange as shown in the illustration.

Standard thickness:

4.8 to 5.2 mm (0.189 to 0.204 in.)

1. If the thickness is not as specified, replace the output shaft.
   

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

Standard inside diameter:

44.015 to 44.040 mm (1.7329 to 1.7339 in.)

Maximum inside diameter:

44.040 mm (1.7339 in.)

1. If the inside diameter is more than the maximum, replace the 3rd gear with a new one.
   

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

Standard inside diameter:

53.015 to 53.040 mm (2.0872 to 2.0881 in.)

Maximum inside diameter:

53.040 mm (2.0881 in.)

1. If the inside diameter is more than the maximum, replace the 2nd gear with a new one.
   

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

Standard inside diameter:

46.015 to 46.040 mm (1.812 to 1.8126 in.)

Maximum inside diameter:

46.040 mm (1.8126 in.)

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

Using a micrometer, measure the thickness of the thrust washer.

Standard thickness:

5.95 to 6.05 mm (0.235 to 0.238 in.)

Minimum thickness:

5.95 mm (0.235 in.)

1. If the thickness is less than the minimum, replace the 1st gear thrust washer.
   

Apply gear oil to the cone of the 1st gear, and check that the No. 1 synchronizer ring set does not turn in either direction while pushing the No. 1 synchronizer ring set.

1. If No. 1 synchronizer ring set turns, replace it.
   

Measure the clearance between the No. 1 synchronizer ring and 1st gear while pushing the No. 1 synchronizer ring against the cone of the 1st gear.

Standard clearance:

0.75 to 1.65 mm (0.0295 to 0.0650 in.)

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

Apply gear oil to the cone of the 2nd gear, and check that No. 1 synchronizer ring set does not turn in either direction while pushing the No. 1 synchronizer ring set.

1. If No. 1 synchronizer ring set turns, replace it.
   

Push the No. 1 synchronizer ring set against the cone of the 2nd gear. Measure the clearance between the No. 1 synchronizer ring set and 2nd gear.

Standard clearance:

0.65 to 1.75 mm (0.0256 to 0.0689 in.)

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

Apply gear oil to the cone of the 3rd gear, and check that No. 2 synchronizer ring does not turn in either direction while pushing the No. 2 synchronizer ring.

1. If the No. 2 synchronizer ring turns, replace it.
   

Push the No. 2 synchronizer ring against the cone of the 3rd gear. Measure the clearance between the No. 2 synchronizer ring (for the 3rd gear) and 3rd gear.

Standard clearance:

0.75 to 1.65 mm (0.0295 to 0.0650 in.)

1. If the clearance is not as specified, replace the No. 2 synchronizer ring with a new one.
   

Using a vernier caliper, measure the groove of the No. 1 shift fork and the thickness of flange of the reverse gear. Then calculate the clearance between the No. 1 shift fork and flange.

Standard clearance:

0.15 to 0.41 mm (0.00591 to 0.0161 in.)

1. If the clearance is not as specified, replace the reverse gear and No. 1 shift fork with new ones.
   

Check the sliding condition between the No. 1 clutch hub and reverse gear.

Check the spline of the reverse gear for wear.

1. If there are any defects, replace the No. 1 clutch hub.
   

Using a vernier caliper, measure the groove of the No. 2 hub sleeve and the thickness of claw of the No. 2 shift fork. Then calculate the clearance between the No. 2 hub sleeve and the claw.

Standard clearance:

0.15 to 0.35 mm (0.00591 to 0.0138 in.)

1. If the clearance is not as specified, replace the No. 2 hub sleeve and No. 2 shift fork with new ones.
   

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

Check the splines of the No. 1 clutch hub for wear.

Check the tip of the spline gear sleeve of the reverse gear for wear.

1. If there are any defects, replace the No. 1 clutch hub or reverse gear.