SECONDARY SHAFT NO.1 COMPONENT INSPECTION

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Gear Inspection

1.   Inspect the gears for damage, wear, or loss.

•  If there is any malfunction, replace the gear.

2.  Inspect the gears and synchronizer rings for damage and wear on contact surfaces.

•  If there is any malfunction, replace the gear.

3.  Measure the inner diameter of the gear using a cylinder gauge in X and Y directions as shown in the figure.

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•  If it exceeds the maximum specification, replace the gear.

Inner diameter of gear

Measurement location

Specification (mm {in})

Maximum (mm {in})
Secondary 3rd gear
43.413 {1.7092}
43.425 {1.7096}
Secondary 4th gear
57.015 {2.2447}
57.030 {2.2453}
Reverse gear
45.948 {1.8090}
45.955 {1.8093}

4.  Measure the outer diameter of the reverse gear using the micrometer in X and Y directions as shown in the figure.

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•  If it is less than the minimum specification, replace the reverse gear.
Outer diameter of reverse gear
Specification: 52.981 mm {2.0859 in}
Minimum: 52.971 mm {2.0855 in}


Secondary Shaft No.1 Inspection

1.  Inspect the spline for damage and wear.

•  If there is any malfunction, replace the secondary shaft No.1.

2.  Inspect the gear area for damage, wear, and loss.

•  If there is any malfunction, replace the secondary shaft No.1.

3.  Measure the runout of the secondary shaft No.1.

(1)   Set the secondary shaft No.1 on V-blocks so that the V-blocks support the secondary shaft No.1 journal as shown in the figure.
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(2)   Measure the runout of the position shown in the figure for the secondary shaft No.1 using a dial gauge.
•  If it exceeds the maximum specification, replace the secondary shaft No.1.
Runout of secondary shaft No.1
Maximum: 0.030 mm {0.0012 in}

4.  Measure the outer diameter of the secondary shaft No.1 using a micrometer. Measurement positions total four and are in the X and Y directions, at four points (A and B) as shown in the figure.

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•  If it is less than the minimum specification, replace the secondary shaft No.1.

Outer diameter of secondary shaft No.1

Measurement location

Specification (mm {in})

Minimum (mm {in})
A: Secondary 3rd gear assembly part
43.358 {1.7070}
43.345 {1.7065}
B: Reverse gear assembly part
45.983 {1.8104}
45.975 {1.8100}


Synchronizer Ring Inspection

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

•  If there is any malfunction, replace the synchronizer ring.

2.  Inspect the taper surface for wear or loss.

•  If there is any malfunction, replace the synchronizer ring.

3.  While holding the synchronizer ring and gear with your fingers as shown in the figure, measure the clearance of the synchronizer ring and gear side surface around the entire circumference using a thickness gauge.

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•  If it is less than the minimum specification, replace the synchronizer ring.

Clearance between synchronizer ring and gear

Measurement location

Specification (mm {in})

Minimum (mm {in})
Synchronizer ring (3GR)
1.145 {0.04508}
0.40 {0.01575}
Synchronizer ring (4GR)
1.145 {0.04508}
0.40 {0.01575}


Clutch Hub Component Inspection

1.  Inspect the clutch hub sleeve and clutch hub operation.

•  If there is any malfunction, replace the malfunctioning part.

2.  Inspect the spline for damage, wear or loss.

•  If there is any malfunction, replace the malfunctioning part.

3.   While holding the clutch hub sleeve and shift fork together with your hand as shown in the figure, measure the clearance between the shift fork and clutch hub sleeve groove using a thickness gauge.

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•  If it exceeds the maximum, replace the clutch hub sleeve and shift fork as a set.

Clearance between shift fork and clutch hub sleeve groove

Measurement location

Specification (mm {in})

Maximum (mm {in})
Shift fork (3GR/4GR)
0.225 {0.00886}
0.40 {0.0157}