Gear and Synchronizer

Fig. 126:

Install the needle bearings in the first, second, third and counter fifth gears. Install the 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 0.16 mm (0.0063 inch) maximum.

Fig. 127:

Check synchronizer ring wear. Insert each ring in matching gear. Measure clearance between each ring and gear with feeler gauge. Clearance should be 0.06 - 1.6 mm (0.024 - 0.063 inch).

Fig. 128:

Check shift fork--to-synchronizer hub clearance with a feeler gauge. Replace the fork if clearance exceeds 1.0 mm (0.039 inch).

Fig. 129:

Check the condition of the reverse idler gear bushing. Replace the gear if the bushing is damaged or worn.