SHIFT FORK, SHIFT ROD AND REVERSE GEAR PARTS INSPECTION

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Spring Inspection

1. Measure the free length of the spring.

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Spring for detent ball

Standard: 19.1 mm {0.751 in}

• If not within the standard, replace the spring.

Intermediate Housing Inspection

1. Measure the height of the intermediate housing pin.

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Intermediate housing pin height

Standard: 9—10 mm {0.36—0.39 in}

• If not within the standard, replace the intermediate housing.

Shift Fork (Reverse) Inspection

1. Using a thickness gauge, measure the clearance between the shift fork and clutch hub sleeve groove.

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Clearance between clutch hub sleeve and shift fork

Standard: 0.2—0.3 mm {0.008—0.011 in}

Maximum: 0.5 mm {0.02 in}

• If it exceeds the maximum specification, replace the shift fork and clutch hub sleeve.

Each Gear Inspection

1. Inspect the following: If there is any malfunction, replace the malfunctioning part.

• Inspect the wear of the synchronizer cone.

• Inspect the teeth of each gear for damage, wear, or loss.

• Inspect for wear and damage to and around the hub sleeve.

• Inspect the teeth of the synchronizer ring for damage, wear, or loss.

Clutch Hub Component Inspection

1. Inspect the following: If there is any malfunction, replace the clutch hub component.

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• Inspect the list of operations when installing the clutch hub sleeve to the hub (reverse gear).

• Inspect the teeth of each gear for damage, wear, or loss.

Synchronizer Ring (Reverse) Inspection

1. Inspect the following: If there is any malfunction, replace the synchronizer ring.

• Inspect the teeth of the synchronizer ring for damage, wear, or loss.

• Inspect the taper surface for wear or loss.

2. Measure the clearance between the sides of the synchronizer ring (reverse) and the reverse synchronizer cone around the entire circumference using a thickness gauge.

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Clearance between sides of synchronizer ring (reverse) and reverse synchronizer cone

Standard: 1.5 mm {0.059 in}

Maximum: 0.8 mm {0.031 in}

• If it exceeds the maximum specification, replace the synchronizer ring.