Unit Inspection and Repair
Inspection and Repair1. Make the necessary repair or parts replacement if wear, damage or any other abnormal conditions are found during inspection.
2. Wash all parts thoroughly in clean solvent. Be sure all old lubricant' metallic particles, dirt, or foreign material are removed from the surfaces of every part. Apply compressed air to each oil feed port and channel in each case half to remove any obstructions or cleaning solvent residue.
Gears
1. Inspect all the gear teeth for signs of excessive wear or damage and check all the gear splines for burrs, nicks, wear or damage. Remove the minor nicks or scratches on an oil stone. Replace any part exhibiting excessive wear or damage.
Front Output Gear Inside Diameter
1. Use an inside dial indicator to measure the gear inside diameter.
2. If the measured value exceeds the specified limit, the gear must be replaced.
Gear inside diameter
Standard: 48.000 - 48.013 mm (1.8898 - 1.8903 inch)
Limit: 48.10 mm (1.894 inch)
Clutch Hub Spline Play
1. Set a dial indicator to the clutch hub to be measured
2. Move the clutch hub as far as possible to both the right and the left.
Note the dial indicator reading.
3. If the measured value exceeds the specified limit, the clutch hub must be replaced.
Clutch hub spline play
Standard: 0 - 0.1 mm (0 - 0.004 inch)
Limit: 0.2 mm (0.008 inch)
Bearings
1. Inspect the condition of all the needles and ball bearings. Wash bearings thoroughly in a cleaning solvent. Apply compressed air to the bearings.
Note: Do not allow the bearings to spin. Turn them slowly by hand. Spinning bearings may damage the rollers.
2. Lubricate the bearings with a light oil and check them for roughness by slowly turning the race by hand.
Ball Bearing Play
1. Use a dial indicator to measure the ball bearing play.
2. If the measured value exceeds the specified limit, the ball bearing must be replaced.
Limit: 0.2 mm (0.008 inch)
Synchronizers
The synchronizer hubs and sliding sleeves are a selected assembly and should be kept together as originally assembled.
Clean synchronizer components with clean solvent and air dry.
Inspect the components for the following:
- Teeth for wear, scuffs, nicks, burrs or breaks.
- Keys and springs for wear, cracks or distortion, replace if these conditions are present.
- If scuffed, nicked or burred conditions cannot be corrected with a soft stone or crocus cloth, replace the component.
Block Ring and Insert Clearance
1. Use a vernier caliper to measure the clearance between the block ring and the insert.
2. If the measured value exceeds the specified limit, the block ring and the insert must be replaced.
Block ring and insert clearance
Standard: 2.46 - 2.74 mm (0.097 - 0.108 inch)
Limit: 3.0 mm (0.118 inch)
2WD-4WD Synchronizer (3-Cone)
1. Use a thickness gauge to measure the clearance between the block ring and the dog teeth.
2. If the measured value exceeds the specified limit, the 2WD-4WD synchronizer assembly must be replaced.
Block ring and insert clearance
Standard: 1.5 mm (0.059 inch)
Limit: 0.8 mm (0.031 inch)
Clutch Hub and Insert Clearance
1. Use a thickness gauge to measure the clearance between the clutch hub and the insert.
2. If the measured value exceeds the specified limit, the clutch hub and the insert must be replaced.
Clutch hub and insert clearance
Standard: 0.01 - 0.19 mm (0.0004 - 0.0075 inch)
Limit: 0.3 mm (0.012 inch)
Detent Springs
1. Inspect the springs for distortion, cracks or wear. Replace if these conditions are present.
Detent Spring Free Length
1. Use a vernier caliper to measure the detent spring free length.
2. If the measured value is less than the specified limit, the detent spring must be replaced.
Detent spring free length
Detent ball
Standard:
Inner 23.2 mm (0.91 inch)
Outer 26.8 mm (1.06 inch)
Limit:
Inner 22.6 mm (0.84 inch)
Outer 26.2 mm (1.03 inch)
Interlock pin
Standard: 15.9 mm (0.626 inch)
Limit: 15.3 mm (0.602 inch)
Detent Spring Tension
1. Use a spring tester to measure the detent spring tension.
2. If the measured value is less than the specified limit, the detent spring must be replaced.
Detent ball
Compressed height: 19.7 mm (0.776 inch)
Standard:
Inner 22.6 - 32.4 N (5.1 - 7.3 lb)
Outer 91.2 - 101.0 N (20.5 - 22.7 lb)
Interlock pin
Compressed height: 11.5 mm (0.453 inch)
Standard: 9.8 N (2.2 lb)
Shift Arm
1. Inspect the shift arms for wear, distortion or scoring. Replace if these conditions are present.
Shift Arm Thickness
1. Use a micrometer to measure the shift arm thickness.
2. If the measured value is less than the specified limit, the shift arm must be replaced.
Shift arm thickness
Standard: 9.60 - 9.85 mm (0.378 - 0.388 inch)
Limit: 9.0 mm (0.354 inch)