Inspection of Transmission Components

1. INSPECT OUTPUT SHAFT




a. Using a micrometer, measure the output shaft flange thickness.

Minimum thickness: 4.70 mm (0.1850 in.)




b. Using a micrometer, measure the outer diameter of the output shaft journal.

Minimum diameter:
A 1st gear 38.860 mm (1.5299 in.)
B 2nd gear 46.860 mm (1.8449 in.)
C 3rd gear 37.860 mm (1.4905 in.)




c. Using a dial indicator, check the shaft runout.

Maximum runout: 0.06 mm (0.0024 in.)




2. INSPECT COUNTER GEAR
Using a micrometer, measure the outer diameter of the counter gear journal.

Minimum diameter: 27.860 mm (1.0968 in.)




3. CHECK OIL CLEARANCE OF EACH GEAR
Using a dial indicator, measure the oil clearance between the gear and shaft with the needle roller bearing installed.

Standard clearance:
1st gear 0.020 - 0.073 mm(0.0008 - 0.0029 in.)
2nd, 3rd and counter 5th gears
0.015 - 0.068 mm(0.0006 - 0.0027 in.)
Maximum clearance: 0.16 mm (0.0063 in.)

If the clearance exceeds the limit, replace the gear, needle roller bearing or shaft.
4. INSPECT SYNCHRONIZER RINGS




a. Turn the ring and push it in to check the braking action.




b. Measure the clearance between the synchronizer ring back and the gear spline end.

Standard clearance: 0.8 - 1.6 mm(0.031 - 0.063 in.)
Minimum clearance: 0.6 mm (0.024 in.)

If the clearance is less than the limit, replace the synchronizer ring.




5. MEASURE CLEARANCE OF SHIFT FORKS AND HUB SLEEVES
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.

Maximum clearance: 1.0 mm (0.039 in.)

If the clearance exceeds the limit, replace the shift fork or hub sleeve.
6. IF NECESSARY, REPLACE INPUT SHAFT BEARING




a. Using snap ring pliers, remove the snap ring.




b. Using a press, remove the bearing.




c. Using SST and a press, install a new bearing.
SST 09506-35010







d. Select a snap ring that will allow minimum axial play and install it on the shaft.
7. IF NECESSARY, REPLACE FRONT BEARING RETAINER OIL SEAL




a. Using a screwdriver, pry out the oil seal.




b. Using SST, drive in a new oil seal.
SST 09608-35014 (09608-06020, 09608-06090)

Drive in depth: 11.2 - 12.2 mm (0.441 - 0.480 in.) from transmission case installation surface

c. Coat the lip of the oil seal with MP grease.




8. IF NECESSARY, REPLACE COUNTER GEAR FRONT BEARING
a. Using snap ring pliers, remove the snap ring.
b. Using SST, press out the bearing.
SST 09950-00020
c. Replace the side race.




d. Using a 24-mm socket wrench, press in the bearing and inner race.







e. Select a snap ring that will allow minimum axial play and install it on the shaft.
9. IF NECESSARY, REPLACE SPEEDOMETER DRIVEN GEAR OIL SEAL




a. Using SST, pull out the oil seal.
SST 09921-00010




b. Using SST, drive in a new oil seal into the sleeve.
SST 09201-60011

Drive in depth: 25 mm (0.98 in.)

10. IF NECESSARY, REPLACE EXTENSION HOUSING OIL SEAL




a. Remove the dust deflector.
b. Using a screwdriver, pry out the oil seal.




c. Using SST, drive in a new oil seal.
SST 09325-40010
d. Coat the lip of the oil seal with MP grease.
e. Install the dust deflector.
11. IF NECESSARY, REPLACE REVERSE RESTRICT PIN




a. Using a torx socket wrench, remove the screw plug.




b. Using a pin punch and hammer, drive out the slotted spring pin.
c. Replace the reverse restrict pin.
d. Using a pin punch and hammer, drive in the slotted spring pin.
e. Apply sealant to the plug threads.
Sealant: Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent




f. Using a torx socket wrench, install and torque the screw plug.

Torque: 190 kg-cm (14 ft-lb, 19 N-m)