Inspection

GEAR COMPONENTS

Inspection


GEAR AND SHAFT






If the contact surface on each gear, mainshaft, main drive gear, and counter gear, etc., has damage, peeling, abrasion, dent, bent, or any other damage, replace the components.






SYNCHRONIZERS






- If the contact surface on coupling sleeve, synchronizer hub, and shifting insert has damage or abrasion, replace the components.
- Coupling sleeve and synchronizer hub shall move smoothly.





- If the cam surface on baulk ring or contact surface on insert has damage or excessive wear, replace with a new one.
- If spread spring damaged, replace with a new one.
-Reverse Synchronizer





Push baulk ring on the cone, and measure the clearance between baulk ring and cone. If the measurement is below limit, replace it with a new one.

Clearance
Standard value Refer to "Baulk Ring Clearance"
Limit valueBaulk Ring Clearance

BAULK RING CLEARANCE

-Single Cone Synchronizer (5th and 6th)





Push baulk ring on the cone, and measure the clearance between baulk ring and cone. If the measurement is below limit, replace it with a new one.

Clearance
Standard valueBaulk Ring Clearance
Limit valueBaulk Ring Clearance

-Double Cone Synchronizer (1st, 3rd and 4th)





Check the clearance between outer baulk ring, synchronizer cone, and inner baulk ring as follows.

CAUTION:
The clearances (A) and (B) are controlled with outer baulk ring, synchronizer cone, and inner baulk ring as a set.
Replace them as a set if the clearances are outside the limit value.





1.Measure the clearance (A) at 2 points or more diagonally opposite using a dial indicator and Tool. Then calculate the mean value.
Tool number: ST-30031000 (J-22912-01)

Clearance (A)
Standard valueBaulk Ring Clearance
Limit valueBaulk Ring Clearance






2.Measure the clearance (B) at 2 points or more diagonally opposite using a feeler gauge. Then calculate the mean value.

Clearance (B)
Standard value
1stBaulk Ring Clearance
3rd,4thBaulk Ring Clearance
Limit valueBaulk Ring Clearance






-Triple Cone Synchronizer (2nd)
Check the clearance between outer baulk ring, synchronizer cone, and inner baulk ring as follows.

CAUTION:
The clearances (A), (B) and (C) are controlled with outer baulk ring, synchronizer cone, and inner baulk ring as a set.
Replace them as a set if the clearances are outside the limit value.





1.Measure the clearance (A) at 2 points or more diagonally opposite using a feeler gauge when pressing baulk ring toward clutch gear taper cone. Then calculate the mean value.

Clearance (A)
Standard valueBaulk Ring Clearance
Limit valueBaulk Ring Clearance






2.Measure the clearance (B) at 2 points or more diagonally opposite using a feeler gauge. Then calculate the mean value.

Clearance (B)
Standard valueBaulk Ring Clearance
Limit valueBaulk Ring Clearance






3.Measure the clearance (C) at 2 points or more diagonally opposite using a feeler gauge when pressing baulk ring toward clutch gear taper cone. Then calculate the mean value.

Clearance (C)
Standard valueBaulk Ring Clearance
Limit valueBaulk Ring Clearance


BEARINGS






If the bearing does not rotate smoothly or the contact surface on ball or race is damaged or peeled, replace with new ones.