Inspection

Check the following parts, 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




1. Worn or damaged gear contact surface.
2. Worn or damage splines.
3. Worn teeth.
4. Clogged oil passage.
5. Primary shaft gear run-out.

Run-out: 0.035 mm (0.0014 in) max.

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




Outer diameter:
A. 41.80-41.99 mm (1.646-1.653 in)
B. 36.75-37.00 mm (1.447-1.457 in)
C. 36.17-36.20 mm (1.424-1.425 in)




Inner diameter (gears):
3rd. 47.00-47.02 mm (1.850-1.851 in)
4th. 47.00-47.02 mm (1.850-1.851 in)
5th. 43.00-43.02 mm (1.693-1.694 in)

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.

Run-out: 0.03 mm (0.0012 in) max.

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




Outer diameter:
A. 42.80-42.91 mm (1.685-1.689 in)
B. 36.95-37.11 mm (1.455-1.461 in)




Inner diameter (gears):
1st. 48.00-48.02 mm (1.890-1.891 in)
2nd. 50.00-50.02 mm (1.968-1.969 in)

Bearing




1. Roughness or noise while turning.
2. Damaged bearing
3. Worn bearing.

Synchronizer Ring




1. Engagement with gear.
2. Worn or damaged teeth.
3. Worn or damaged tapered surface.
4. Clearance from the side of gear.

Clearance: 1.5 mm (0.059 in)
Minimum: 0.8 mm (0.031 in)

NOTE:
a. Place the synchronizer ring on the gear cone and rotate until it stops (approx. 10 to 20 degrees), then measure around the circumference.
b. If the clearance is less than specified replace the synchronizer ring or gear.

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 installed.

Clutch Hub Sleeve

Clearance:

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

Reverse Idle Gear




1. Worn or damaged bushing.
2. Worn or damaged teeth.
3. Worn or damaged reverse shift lever coupling groove.
4. Clearance between gear and reverse shift lever.

Clearance: 0.095-0.318 mm (0.00619-0.0125 in)
Maximum: 0.368 mm (0.0145 in)

Clutch Housing and Transaxle Case
Cracks or damage.






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

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.