12. Shift Shaft and Shift Fork Cleaning and Inspection

Shift Shaft and Shift Fork Cleaning and Inspection




1. Clean all of the shift parts in a suitable cleaning solvent and air dry the parts.
2. Roll the shift shafts on a flat surface to inspect them for being bent.
3. Inspect the shift shafts for wear or scoring.
4. If light scoring is present, dress the area using a soft stone. Do not use a file.
5. Inspect the roll pin in the shift shaft gate (b) for being loose.
6. Inspect the gates (a) for damage or wear.
7. Inspect the shift shaft detents (c) for excessive rounding, chipping or distortion.
8. Replace the shift shaft if faulty.




9. Inspect the 1st/2nd shift fork for scoring, distortion, or wear through the hardened surface.
10. Inspect for a bent shift fork.
11. Inspect for cracks in the shift fork.
12. Inspect the shift rail holes for excessive wear.
13. Replace the shift fork if faulty.




14. Using a feeler gauge, measure the clearance between the reverse gear and the shift fork.

Maximum Clearance: 1.0 mm (0.039 in)

15. If the clearance exceeds the maximum, replace the shift fork or the reverse gear.




16. Inspect the 3rd/4th shift fork for scoring, distortion, or wear through the hardened surface.
17. Inspect for a bent shift fork.
18. Inspect for cracks in the shift fork.
19. Inspect the shift rail hole for excessive wear.
20. Replace the shift fork if faulty.




21. Using a feeler gauge, measure the clearance between the 3rd/4th synchronizer sleeve and the shift fork.

Maximum Clearance: 1.0 mm (0.039 in)

22. If the clearance exceeds the maximum, replace the shift fork or the sleeve.




23. Inspect the reverse shift fork and the reverse shift lever for wear or damage.
24. Replace the reverse shift fork or the reverse shift lever if found faulty.




25. Using a feeler gauge, measure the clearance between the reverse idler gear and the reverse shift fork.

* Standard Clearance: 0.05-0.35 mm (0.0020-0.0138 in)
* Maximum clearance: 0.50 mm (0.0197 in)

26. If the clearance exceeds the maximum, replace the shift fork or the reverse idler gear.




27. Inspect the 5th gear shift fork for worn pads.
28. Inspect for a bent shift fork.
29. Inspect for cracks in the shift fork.
30. Inspect the shift rail hole for excessive wear.
31. Inspect the shift fork gates for excessive wear.
32. Replace the shift fork if faulty.




33. Using a feeler gauge, measure the clearance between the 5th synchronizer sleeve and the shift fork.

Maximum Clearance: 1.0 mm (0.039 in)

34. If the clearance exceeds the maximum, replace the shift fork or the sleeve.




35. Inspect the interlocks for excessive wear.
36. Inspect the detent springs for distortion.
37. Inspect the shift detent balls for wear.
38. Replace the faulty parts.




39. Roll the shift control shaft on a flat surface to inspect it for being bent.
40. Inspect the shaft for wear or scoring.
41. If light scoring is present, dress the area using a soft stone. Do not use a file.
42. Inspect the shift control shaft for wear at the control lever.
43. Replace the shift control shaft if faulty.
44. Inspect the internal shift control lever for damage or excessive wear.
45. Replace the internal shift control lever if faulty.