Inspection

INSPECTION OF OUTPUT SHAFT ASSEMBLY
1. MEASURE EACH GEAR THRUST CLEARANCE
Measure the thrust clearance of each gear.
Standard clearance:
0.10 - 0.25 mm (0.0039 - 0.0098 in.)
Maximum clearance:
0.25 mm (0.0098 in.)





2. MEASURE EACH GEAR OIL CLEARANCE
Using a dial indicator, measure the each gear oil clearance.
Standard clearance:
0.009 - 0.32 mm (0.0004 - 0.0013 in.)
Maximum clearance:
0.032 mm (0.0013 in.)





3. INSPECT OUTPUT SHAFT AND INNER RACE
(a) Using calipers, measure the output shaft flange thickness.
Minimum thickness: 4.80 mm (0.1890 in.)





(b) Using calipers, measure the inner race flange thickness.
Minimum thickness: 3.99 mm (0.1571 in.)





(c) Using a micrometer, measure the outer diameter of the output shaft journal.
Minimum diameter:
2nd gear 37.984 mm (1.4954 in.)
3rd gear 34.984 mm (1.3773 in.)





(d) Using a micrometer, measure the outer diameter of the inner race.
Minimum diameter: 38.985 mm (1.5348 in.)





(e) Using a dial indicator, check the shaft runout.
Maximum runout: 0.05 mm (0.0020 in.)





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:
1.0 - 2.0 mm (0.039 - 0.079 in.)
Minimum clearance:
0.8 mm (0.031 in.)





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.)