Manual Transmission/Transaxle: Testing and Inspection

GENERAL INSPECTION
Inspect transmission case and housing for cracks, worn or damaged bores, damaged threads or any other damage that could cause improper alignment of transmission with flywheel housing. Remove small nicks or burrs, using a suitable fine stone. Inspect bellhousing for cracks. Ensure machined mating surfaces are free from burrs, nicks or other damage.

Check condition of shift covers, forks, shift rails and shafts. Inspect ball bearings for cracks or deformations and replace any roller bearings that are broken, worn or rough.

SYNCHRONIZER RING - INSPECTION

Synchronizer Clearance Chart:

Position synchronizer ring on synchronizer body as shown. Insert a suitable feeler gauge, then measure clearance at two opposite points. If clearance is less than 0.024 inch, for 3rd/4th, 1st/2nd and 5th synchronizer assemblies and 0.008 inch for reverse synchronizer assembly, replace synchronizer ring, synchronizer body or both. Check length of all synchronizers compression springs. Unloaded length of spring should be 0.583 inch, O.D. should be 0.235 inch and wire diameter should be 0.037 inch.