SECONDARY SHAFT (NO.2) COMPONENTS INSPECTION

Synchronizer Ring, Secondary Shaft (No.2) and Gear Inspection

1. Inspect the shaft for damage, abnormal wear, dents, flaking, or bending.

• If there is a malfunction, replace the shaft.

2. Inspect the gears for damage, abnormal wear, dents, flaking, or bending.

• If there is any malfunction, replace the gear.

3. Inspect the oil passage for clogging.

• If there is any malfunction, replace parts if necessary.

4. Inspect the tapered surface for abnormal wear and cracks.

• If there is any malfunction, replace parts if necessary.

5. Inspect the synchronizer ring teeth and grooves for damage, abnormal wear, and cracks.

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

Clutch Hub Component Inspection

1. Verify that the clutch hub sleeve and clutch hub move smoothly.

• If there is any malfunction, replace parts if necessary.

Synchronizer Ring Clearance Inspection

1. Set the synchronizer ring evenly in the gear, and measure the clearance between the synchronizer ring and flank surface of the gear all around the circumference using a feeler gauge.

Synchronizer Ring clearance

(mm {in})

Gear	Clearance
5th, 6th	0.80-1.60 {0.0315-0.0629}
Reverse	0.68-1.32 {0.0268-0.0519}

• If not within the specification, replace the synchronizer ring.

Clutch Hub Sleeve and Shift Fork Inspection

1. Measure the shift fork thickness (or groove width) and the groove width (or thickness) of the clutch hub sleeve with a vernier caliper, and calculate the clearance.

Clutch hub sleeve and shift fork clearance

(mm {in})

Gear	Clearance
5th/6th	0.10-1.50 {0.0039-0.0590}
Reverse	0.15-0.41 {0.0059-0.0161}

• If not within the specification, replace the clutch hub sleeve and shift fork.