Inspection

Check the following parts, and replace if necessary.




1st, 2nd, 3rd, 4th, and 5th Gears
1. Worn or damaged synchronizer cone
2. Worn or damaged hub sleeve coupling
3. Worn or damaged teeth
4. Worn or damaged inner surface or end surface of gears

Primary Shaft Gear and Primary Gear (5-speed)




1. Worn teeth
2. Worn or damaged sliding parts of each gear
3. Worn or damaged spline
4. Clogged oil passage

NOTE: When the shaft gear is replaced, adjust the bearing pre-load




Synchronizer Ring
1. Engagement with gear

CAUTION: If meshing is not good, coat the gear and the synchronizer ring contact surfaces with compound and repair by lapping.

2. Worn or damaged spline
3. Worn or damaged tapered surface
4. Clearance from the side of gear

Standard: 1.5 mm (0.0591 in)
Limit: 0.8 mm (0.0315 in)

CAUTION:
a. Press the synchronizer ring uniformly against the gear and measure the overall circumference.
b. If the measured value is less than the limit, replace the synchronizer ring or gear.

Secondary Shaft Gear




1. Worn or damaged gear sliding parts
2. Worn or damaged splines
3. Worn teeth
4. Clogged oil passage

CAUTION: If the shaft gear is replaced, adjust the bearing pre-load.

Clutch Hub




1. Worn or damaged sleeve sliding surface
2. Worn or damaged synchronizer key groove
3. Worn end surface
4. Operation of the hub sleeve when it is installed

Clutch Hub Sleeve
1. Worn or damaged hub sliding surface
2. Worn or damaged sleeve fork groove

Synchronizer Key and Spring
1. Worn key
2. Weak or bent spring

Reverse Idle Gear
1. Worn or damaged bushing
2. Worn or damaged teeth
3. Worn or damaged release lever coupling groove

Clutch housing, Transaxle case, Rear cover, and Differential Gear Case
1. Cracks or damage

CAUTION: If the clutch housing, transaxle case, or differential gear case are replaced, adjust the bearing pre-load of each shaft gear and the pre-load of the differential side bearing.

Bearing




1. Roughness or noise while turning
2. Worn or damaged outer race or roller

CAUTION:
a. Replace the bearing, the outer race, and the inner race all together.
b. If the bearing is replaced, adjust the pre-load.

Ring Gear and Speedometer Drive Gear




1. Worn or damaged teeth

NOTE: If the ring gear is faulty, replace the entire ring gear and gear case assembly.

Oil Seal
1. Deformed, damaged, or worn lip

Speedometer Driven Gear Assembly
1. Worn or damaged teeth
2. Worn or damaged O-ring

Backlash of Side Gear and Pinion Gear




Check and adjust by using the following procedure.
1. Install the driveshaft and the joint shaft onto the differential assembly.
2. Support the shafts on V-blocks, as shown.
3. Measure the backlash of both pinion gears.

Standard backlash: 0-0.1 mm (0-0.0039 in)

4. If the backlash exceeds the standard, replace all thrust washers with new ones.

Thrust Clearance of 1st, 2nd, 3rd, and 4th Gears






NOTE: Measure either before disassembling the shaft gear assembly or while assembling it.

1. Measure the clearance between 1st gear and the differential drive gear on the secondary shaft.

Standard: 0.05-0.28 mm (0.0020-0.0110 in)
Limit: 0.505 mm (0.0199 in)




2. Measure the clearance between 2nd gear and the 3rd gear.

Standard: 0.175-0.455 mm (0.0069-0.0179 in)
Limit: 0.505 mm (0.0199 in)




3. Measure the clearance between 3rd gear and the 2nd gear.

Standard: 0.05-0.20 mm (0.0020-0.0079 in)
Limit: 0.25 mm (0.0098 in)




4. Measure the clearance between 4th gear and the bearing inner race.

Standard: 0.165-0.365 mm (0.0064-0.0144 in)
Limit: 0.415 mm (0.0163 in)