Inspection
INSPECTIONOUTPUT SHAFT
Check thickness of the output shaft and inner bearing race flanges (Fig. 51).
- Shaft flange minimum thickness: 4.80 mm (0. 189 in.)
- First gear bearing inner race flange minimum thickness: 3.99 mm (0.157 in.)
Measure diameter of the output shaft journal surfaces. Replace shaft if either of these surfaces are out of specification.
- Second gear surface minimum diameter: 37.964 mm (1.495 in.)
- Third gear surface minimum diameter: 34.984 mm (1.377 in.)
Measure diameter of the first gear bearing inner race. Minimum diameter is 38.985 mm (1.535 in.).
Measure output shaft runout with a dial indicator (Fig. 52). Runout should not exceed 0.05 mm (0.002 in.).
Replace output shaft or first gear inner bearing race if measurement of any surface is out of specification.
COUNTERSHAFT
Inspect countershaft gear teeth. Replace the countershaft if any teeth are worn or damaged. Inspect bearing surfaces and replace shaft if any surface shows damage or wear.
Check condition of the countershaft front bearing. Replace bearing if worn, noisy or damaged.
GEAR AND SYNCHRONIZER
Install needle bearing and inner race in the first gear. Then check oil clearance between the gear and inner race (Fig. 53). Clearance should be 0.009 - 0.032 mm (0.0004 - 0.0010 in.).
Install 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 (Fig. 54). Oil clearance for all three gears is 0.009 - 0.0013 mm (0.0004 - 0.0013 in.).
Check synchronizer ring wear (Fig. 55). 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 in.).
1. Check shift fork to synchronizer hub clearance with a feeler gauge (Fig. 56). Replace fork if clearance exceeds 1.0 mm (0.039 in.).
2. Inspect all mainshaft gear teeth. Replace any gear which shows any worn or damaged teeth.