Inspection and Repair
INSPECTION AND REPAIRMake the necessary repair or parts replacement if wear, damage or any other abnormal conditions are found during inspection.
Wash all parts thoroughly in cleaning solvent. Be sure all old lubricant, metallic particles, dirt, or foreign material are removed from the surfaces of every part. Apply compressed air to each oil feed port and channel in each case half to remove any obstructions or cleaning solvent residue.
GEARS
Inspect all gear teeth for signs of excessive wear or damage and check all gear splines for burrs, nicks, wear or damage. Remove minor nicks or scratches on an oil stone. Replace any part exhibiting excessive wear or damage.
GEAR INSIDE DIAMETER
Use an inside dial indicator to measure the gear inside diameter.
If the measured value exceeds the specified limit, the gear must be replaced.
Gear inside diameter:
Standard 48.000 - 48.013 (1.8898 - 1.8903) mm (in)
Limit 48.10(1.894) mm (in)
CLUTCH HUB SPLINE PLAY
Set dial indicator to the clutch hub to be measured.
Move the clutch hub as far as possible to both the right and the left.
Note the dial indicator reading.
If the measured value exceeds the specified limit, the clutch hub must be replaced
Clutch hub spline play:
Standard 0-0.1 (0-0004) mm (in)
Limit 0.2 (0.008) mm (in)
BEARINGS
Inspect the condition of all needles, and ball bearings. Wash bearings thoroughly in cleaning solvent. Apply compressed air to bearings.
Do not allow the bearings to spin. Turn them slowly by hand. Spinning bearings may damage the rollers.
Lubricate bearings with a light oil and check them for roughness by slowly turning the race by hand.
BALL BEARING PLAY
Use a dial indicator to measure the ball bearing play.
If the measured value exceeds the specified limit, the ball bearing must be replaced.
Limit 0.2 (0.008) mm (in)
SYNCHRONIZERS (M/T)
The synchronizer hubs and sliding sleeves are a selected assembly and should be kept together as originally assembled.
Clean synchronizer components with cleaning solvent and air dry.
Inspect the components for the following:
- Teeth for wear, scuffs, nicks, burrs or breaks.
- Keys and springs for wear, cracks or distortion, replace if these conditions are present.
- If scuffed, nicked or burred conditions cannot be corrected with a soft stone or crocus cloth, replace the component.
2WD-4WD SYNCHRONIZER (3- CONE)
- Use a thickness gauge to measure the clearance between the block ring and the dog teeth.
- If the measured value exceeds the specified limit, the 2WD - 4WD synchronizer assembly must be replaced
Block ring and dog teeth clearance
Standard 1.5 (0.059) mm (in)
Limit 0.8 (0.031) mm (in)
BLOCK RING AND INSERT CLEARANCE
Use a vernier caliper to measure the clearance between the block ring and the insert.
If the measured value exceeds the specified limit, the block ring and the insert must be replaced Block ring and insert clearance mm (in)
Standard 4.34 4.66 (0.171 - 0.183) mm (in)
Limit 4.9 (0.193)mm (in)
BLOCK RING AND DOG TEETH CLEARANCE
Use a thickness gauge to measure the clearance between the block ring and the dog teeth.
If the measured value is less than the specified limit, the block ring must be replaced.
Block ring and dog teeth clearance
Standard 1.5 (0.059) mm (in)
Limit 0.8 (0.031) mm (in)
CLUTCH HUB AND INSERT CLEARANCE
Use a thickness gauge to measure the clearance between the clutch hub and the insert.
If the measured value exceeds the specified limit, the clutch hub and the insert must be replaced. Clutch hub and insert clearance
Standard 0.09-0.31(0.0035-0.0122) mm (in)
Limit 0.4 (0.0157) mm (in)
DETENT SPRINGS
Inspect the springs for distortion, cracks or wear. Replace if these conditions are present.
DETENT SPRING FREE LENGTH
Use a vernier caliper to measure the detent spring free length.
If the measured value is less than the specified limit, the detent spring must be replaced. Detent spring free length mm (in)
Detent ball Standard 25.6 (1.008) Limit 25.0 (0.984) mm (in)
Interlock pin Standard 1.59 (0.063) 1.53 Limit (0.060) mm (in)
DETENT SPRING TENSION
Use a spring tester to measure the detent spring tension.
Detent spring tension:
Compressed height mm(in)
Detent ball 20.5 (0.807)
Interlock Pin 11.5 (0.453)
Standard N (lb)
Detent ball 65 - 75 (14.6 - 16.8)
Interlock Pin 9.8 (2.2)
SHIFT ARM
Inspect the shift arms for wear, distortion or scoring. Replace if these conditions are present.
SHIFT ARM THICKNESS
Use a micrometer to measure the shift arm thickness.
If the measured value is less than the specified limit, the shift arm must be replaced.
Shift arm thickness mm (in)
Standard 9.60 - 9.85 (0.378 - 0.388)
Limit 9.0 (0.354)