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, and cracks.
3. Inspect synchronizer ring matching teeth for damage and wear.
4. Inspect main drive gear splines for damage and wear.

Mainshaft





1. Measure the mainshaft runout.

Runout: 0.03 mm (0.0012 in) max..

2. Inspect splines for damage and wear.





3. Measure the clearance between mainshaft and gear (or bushing).

Clearance: 0.15 mm (0.006 in) max.

Countershaft




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




Control Rod Lever and Shift Rod
Measure the clearance between the control rod lever and the shift rod gate.

Clearance: 0.8 mm (0.031 in) max.




Each Clutch Hub Assembly
1. Inspect clutch hub sleeve and hub operation.
2. Inspect individual gear teeth for damage, wear, and cracks.
3. Inspect synchronizer keys for damage, wear, and cracks.




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

Clearance: 0.20.3 mm (0.0080.012 in)
Maximum: 0.5 mm (0.020 in)

Synchronizer Ring (1st, 4th, 5th, Reverse)




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

NOTE: Set the synchronizer ring squarely in the gear.




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

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




Synchronizer Assembly (2nd/3rd)

CAUTION: If any part of the synchronizer assembly is damaged, replace the assembly as a whole.

1. Inspect individual synchronizer ring gear teeth for damage, wear, and cracks.
2. Inspect for wear and damage to the tapered surfaces of the inner cone, double cone, and synchronizer ring.

NOTE: Set the synchronizer assembly squarely in the gear.




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

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




Reverse Idler Gear and Shaft
1. Inspect gear teeth for damage, wear, and cracks.




2. Measure the clearance between the reverse idler gear bushing and shaft.

Clearance: 0.020.05 mm (0.0008 - 0.0020 in)
Maximum: 0.15 mm (0.006 in)




Spring
Measure the free length of the spring.

Standard free length: mm (in)
Detent ball spring: 22.5 (0.886)
5th/Reverse retaining spring: 73.00 (2.874)
Select lock spindle spring: 43.25 (1.703)

Extension Housing




1. Inspect the indicated bearings for damage
2. Replace the extension housing if necessary.