Inspection

Inspect all parts and repair or replace as necessary.




Synchronizer Ring
1. Inspect the synchronizer ring teeth for damage, wear, and cracks.
2. Inspect the tapered surface for wear and cracks.




3. Set the synchronizer ring squarely in the gear.
4. Measure the clearance between the synchronizer ring and the flank surface of the gear.

Standard clearance: 1.88 mm (0.044-0.074 in)
Minimum: 0.8 mm (0.032 in)




Reverse Idler Gear and Reverse Lever
1. Inspect the gear teeth for damage, wear, and cracks.
2. Measure the clearance between the reverse idler gear bushing and the reverse lever.

Standard clearance: 0.10-0.32 mm (0.004-0.013 in)
Maximum: 0.37 mm (0.015 in)




Primary Shaft Gear
1. Measure the shaft gear runout.

Runout: 0.05 mm (0.002 in) max.

2. Inspect the splines for damage and wear.
3. Inspect the gear teeth for damage, wear, and cracks.
4. If the shaft gear is replaced, adjust the bearing preload.







3rd Gear; 4th Gear, 5th Gear; and Gear Sleeve (5th Gear)
1. Determine the clearance between the shaft gears and the gears.




Clearance




2. Inspect the synchronizer cones for wear.
3. Inspect the gear teeth for damage, wear, and cracks.
4. Inspect synchronizer ring matching teeth for damage and wear.




Bearing
Inspect for damage or rough rotation.




Secondary Shaft Gear
1. Measure the shaft gear runout.

Runout: 0.015 mm (0.0006 in) max.

2. Inspect the gear teeth for damage, wear, and cracks.
3. If the shaft gear is replaced, adjust the bearing preload.







1st Gear and 2nd Gear
1. Determine the clearance between the shaft gears and the gears.




Clearance
2. Inspect the synchronizer cones for wear.
3. Inspect the gear teeth for damage, wear, and cracks.
4. Inspect synchronizer ring matching teeth for damage and wear.




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




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




Clearance




Speedometer Driven Gear Assembly
1. Inspect the teeth for damage and wear.
2. Inspect the O-ring for damage and wear.