Inspection

1. Inspect 1st through 5th gears for worn or damaged synchronizer cone, hub sleeve coupling, gear teeth, inner surface or end surface of gears.

Input Shaft Gear Runout Measurement:

2. Inspect input shaft and gear for worn teeth or input gear shaft run-out. Check run-out by mounting gear shaft in a lathe or V-blocks. Check the run-out at the point shown. Correct run-out specification is less than 0.002 inches.
3. Inspect synchronizer ring for the following conditions:
a. Engagement with gear. Ring must engage smoothly with gear.
b. Worn or damaged teeth or tapered surface.
c. Clearance from side of gear. Press the synchronizer ring uniformly against the gear and measure around the circumference. If the measured value is less than 0.031 inch, replace the synchronizer ring or gear.
4. Inspect main shaft for following conditions:
a. Worn or damaged gear contact surfaces, splines or gear teeth.
b. Clogged oil passage.

Main Shaft Gear Runout Measurement:

c. Main shaft gear run-out. Mount gear in a lathe or V-blocks and measure run-out at point shown. Correct run-out specification is 0.0006 inch.
5. Inspect clutch hub for worn or damaged splines, synchronizer key groove or end surface. check for smooth hub sleeve when installed.
6. Inspect clutch hub sleeve for worn or damaged hub splines or sleeve fork groove and excessive clearance between sleeve and shift fork. Correct clearance is 0.008-0.018 inch.
7. Inspect synchronizer keys and springs for worn key and bent springs.
8. Inspect reverse idler gear for worn or damaged bushing, gear teeth or release lever coupling groove. Check for excessive clearance between sleeve and reverse lever. Correct clearance is 0.004-0.020 inch.
9. Inspect clutch housing, transaxle case, rear cover and differential gear case for cracks or other physical damage.
10. Inspect speedometer drive gear assembly for worn or damaged teeth, O-ring, oil seal, lip and ring gear speedometer drive gear.