Inspection

INSPECTION
Check the following pans, 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. Primary shaft gear run-out.

Standard run-out : 0.05 mm (0.002 in)

NOTE: If the shaft gear is replaced, adjust the bearing preload.




Synchronizer Ring
1. Engagement with gear.
2. Worn or damaged teeth.
3. Worn or damaged tapered surface.




4. Clearance from the side of gear.

Standard: 1.5 mm (0.059 in)
Limit: 0.8 mm (0.031 in)

CAUTION
a. Press the synchronizer ring uniformly against the gear and measure around the 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 contact surface.
2. Worn or damaged splines.
3. Worn teeth.
4. Clogged oil passage.
5. Secondary shaft gear run-out.

Standard run-out: 0.015 mm (0.0006 in)




6. Oil clearance between secondary gear shaft and gears.

Standard: 0.03-0.08 mm (0.001-0.003 in)

CAUTION: If the shaft gear is replaced, adjust the bearing preload.




Clutch Hub
1. Worn or damaged splines.
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 splines.
2. Worn or damaged sleeve fork groove.
3. Clearance between sleeve and shift fork.

Standard: 0.2-0.458 mm (0.008-0.018 in)
Limit: 0.5 mm (0.020 in)




Synchronizer Key and Spring
1. Worn key.
2. Bent spring.




Reverse Idle Gear
1. Worn or damaged bushing.
2. Worn or damaged teeth.
3. Worn or damaged release lever coupling groove.
4. Clearance between sleeve and reverse lever.

Standard: 0.095-0.318 mm (0.004-0.013 in)
Limit: 0.5 mm (0.020 in)




Clutch Housing, Transaxle Case, Rear Cover, and Differential Gear Case
Cracks or damage.

CAUTION: If the clutch housing, transaxle case, or differential gear case is replaced, adjust the bearing preload of the shaft gears and the preload of the differential side bearings.




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

CAUTION
a. Replace the bearing, the outer race, and the inner race as a unit.
b. If the bearing is replaced, adjust the preload.




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

Ring Gear Speedometer Drive Gear
Worn or damaged teeth.

Oil Seal
Damaged or worn lip.