1. Main shaft inspection
1) Inspect the main shaft, and if excessive wear or damage is found, replace parts as necessary.
2) Measure the runout of the main shaft center section using a dial gauge.
Note
- Replace the main shaft if the measured value exceeds the limit.
Limit: 0.05 mm { 0.0020 in }
3) Measure the outer diameter of the main shaft using a micrometer.
Note
- Replace the main shaft if the measured value exceeds the limit.
Main shaft outer diameter
| Standard value |
46.980 to 46.991 mm { 1.84960 to 1.85004 in } |
| Limit |
46.980 mm { 1.84960 in } |
| Standard value |
46.980 to 46.991 mm { 1.84960 to 1.85004 in } |
| Limit |
46.980 mm { 1.84960 in } |
| Standard value |
42.980 to 42.991 mm { 1.69212 to 1.69256 in } |
| Limit |
42.980 mm { 1.69212 in } |
| Standard value |
41.980 to 41.991 mm { 1.65275 to 1.65319 in } |
| Limit |
41.980 mm { 1.65275 in } |
Legend
- 3rd gear installation position
- 2nd gear installation position
- 1st gear installation position
- Reverse gear installation position
2. Bearing inspection
1) Measure the play of the main shaft rear bearing using the dial gauge.
Note
- Replace the main shaft rear bearing if the measured value exceeds the standard value.
Standard: 0.2 mm { 0.008 in }
3. Gear inspection
1) Measure the inner diameters of the following gears using an inside dial gauge.
- 1st gear
- 2nd gear
- 3rd gear
- Reverse gear
Note
- Replace the gear if the measured value exceeds the limit.
| Standard value |
53.000 to 53.019 mm { 2.08661 to 2.08736 in } |
| Limit |
53.019 mm { 2.08736 in } |
| Standard value |
53.000 to 53.019 mm { 2.08661 to 2.08736 in } |
| Limit |
53.019 mm { 2.08736 in } |
| Standard value |
49.000 to 49.016 mm { 1.92913 to 1.92976 in } |
| Limit |
49.016 mm { 1.92976 in } |
| Standard value |
48.000 to 48.016 mm { 1.88976 to 1.89039 in } |
| Limit |
48.016 mm { 1.89039 in } |
4. Synchronizer inspection
1. Synchromesh mechanism
1) Inspect the synchromesh mechanism.
Note
- If excessive wear or damage is found during inspection, replace parts as necessary.
2) Measure the clearance between the following block rings and the dog gears using a feeler gauge.
Note
- Replace the block ring if the measured value exceeds the limit.
| Standard value |
1.6 mm { 0.063 in } |
| Limit |
0.8 mm { 0.031 in } |
| Standard value |
1.6 mm { 0.063 in } |
| Limit |
0.8 mm { 0.031 in } |
| Standard value |
1.6 mm { 0.063 in } |
| Limit |
0.8 mm { 0.031 in } |
Legend
- Block ring
- Outside ring
- Inside ring
| Standard value |
1.4 mm { 0.055 in } |
| Limit |
0.8 mm { 0.031 in } |
3) Measure the clearance between the following block rings and clutch hub using a vernier caliper.
Note
- Replace the block ring and clutch hub if the measured value exceeds the limit.
| Standard value |
2.4 to 2.8 mm { 0.094 to 0.110 in } |
| Limit |
2.8 mm { 0.110 in } |
| Standard value |
2.4 to 2.8 mm { 0.094 to 0.110 in } |
| Limit |
2.8 mm { 0.110 in } |
| Standard value |
2.4 to 2.8 mm { 0.094 to 0.110 in } |
| Limit |
2.8 mm { 0.110 in } |
2. Insert inspection
1) Measure the clearance between the following insert and the clutch hub using a vernier caliper.
Note
- Replace the insert and clutch hub if the measured value exceeds the limit.
| Standard value |
0.2 to 0.5 mm { 0.0079 to 0.0197 in } |
| Limit |
0.5 mm { 0.0197 in } |
| Standard value |
0.2 to 0.5 mm { 0.0079 to 0.0197 in } |
| Limit |
0.5 mm { 0.0197 in } |
| Standard value |
0.2 to 0.5 mm { 0.0079 to 0.0197 in } |
| Limit |
0.5 mm { 0.0197 in } |
3. Clutch hub inspection
1) Inspect the following clutch hubs.
- 1st - 2nd clutch hub
- 3rd - 4th clutch hub
- Reverse clutch hub
2) Set the dial gauge to the clutch hub.
3) Move the clutch hub left to right as far as possible.
Note
- Replace the clutch hub if the measured value exceeds the limit.
| Standard value |
0.00 to 0.04 mm { 0.0000 to 0.0016 in } |
| Limit |
0.10 mm { 0.0039 in } |
| Standard value |
0.00 to 0.04 mm { 0.0000 to 0.0016 in } |
| Limit |
0.10 mm { 0.0039 in } |
| Standard value |
0.00 to 0.04 mm { 0.0000 to 0.0016 in } |
| Limit |
0.10 mm { 0.0039 in } |
