Gear and Synchronizer

Fig. 121:

Install the needle bearing and inner race in the first gear. Then check oil clearance between the gear and inner race. Clearance should be 0.009 - 0.032 mm (0.0004 - 0.0013 inch).

Fig. 122:

Install the needle bearings and the second, third and counter fifth gears on the output shaft. Then check oil clearance between the gears and shaft with a dial indicator. Oil clearance for all three gears is 0.009 - 0.0013 mm (0.0004 - 0.0013 inch).

Fig. 123:

Check synchronizer ring wear. Insert each ring in matching gear. Measure clearance between each ring and gear with feeler gauge. Replace ring if clearance exceeds 2.0 mm (0.078 inch).

Fig. 124:

Check shift fork-to-synchronizer hub clearance with a feeler gauge. Replace the fork if clearance exceeds 1.0 mm (0.039 inch).
1. Inspect all mainshaft gear teeth. Replace any gear which shows any worn or damaged teeth.