Inspection

Inspect all parts, and repair or replace as necessary.




Each gear and main drive gear
1. Inspect synchronizer cones for wear.
2. Inspect individual gear teeth for damage, wear, cracks.
3. Inspect synchronizer ring matching teeth for damage or wear.
4. Inspect main drive gear splines for damage or wear.




Mainshaft
1. Measure the mainshaft runout.

Maximum: 0.03 mm (0.0012 in)

2. Inspect splines for damage or wear.
3. Measure the clearance between mainshaft and gear (or bush).

Maximum: 0.15 mm (0.006 in)




Countershaft
1. Inspect gear teeth for damage, wear, cracks.
2. Inspect splines for damage or wear.




Clutch hub assembly
1. Inspect for clutch hub sleeve and hub operation.
2. Inspect individual gear teeth for damage, wear, cracks.
3. Inspect synchronizer key for damage, wear, cracks.




4. Measure the clearance between hub sleeve and shift fork.

Standard clearance: 0.2 - 0.3 mm (0.008 - 0.012 in)
Maximum: 0.5 mm (0.020 in)




Synchronizer ring
1. Inspect individual synchronizer ring teeth for damage, wear, cracks.
2. Inspect taper surface for wear or cracks

NOTE: Set the synchronizer ring squarely in the gear; then measure around the circumference.




3. Measure the clearance between synchronizer ring and flank surface of gear.

Standard clearance: 1.5 mm (0.059 in)
Minimum: 0.8 mm (0.031 in)




Bearing
Inspect for damage or rough rotation.




Reverse idler gear and shaft
1. Inspect gear teeth for damage, wear, cracks.
2. Measure the clearance between reverse idle gear bush and shaft.

Standard clearance: 0.02 - 0.05 mm (0.0008 - 0.0020 in)
Maximum: 0.15 mm (0.006 in)




Springs
Measure the free length of spring.

Standard free length
Shift rod (5th/Reverse) spring: 75 mm (2.953 in)
Detent ball spring (1st/2nd, 3rd/4th): 22.5 mm (0.886 in)
Detent ball spring (5th/Reverse): 17.0 mm (0.669 in)




Intermediate housing
Measure the intermediate housing pin height.

Standard height: 9.0 - 10.0 mm (0.354 - 0.394 in)