Overhaul

INSPECTION
1. Inspect all drive gears for worn or damaged synchronizer cones, hub sleeve couplings, gear teeth, gear inner surfaces, or end surfaces.
2. Inspect input shaft and gear for worn teeth or input gear shaft runout as follows:
a. Mount gear shaft in lathe or V-blocks.

Input Shaft Gear Runout Measurement:

b. Check runout at specified point.
c. Correct runout is less than 0.002 inches.
3. Inspect synchronizer ring as follows:
a. Ensure ring engages smoothly with gear.
b. Ensure teeth are not worn or damaged teeth and surface is not tapered.
c. Measure clearance from side of gear. Press synchronizer ring evenly against gear and measure circumference. If less than 0.031 inch, replace synchronizer ring or gear.
4. Inspect mainshaft as follows:
a. Ensure there are no worn or damaged gear contact surfaces, spline or gear teeth.
b. Ensure oil passages are not clogged.

Mainshaft Gear Runout Measurement:

c. Measure mainshaft gear runout. Mount gear in lathe or V-blocks and measure runout at specified point. Correct runout is 0.0006 inch.
5. Inspect clutch hub for worn or damaged splines, synchronizer key groove or end surface.
6. Inspect clutch hub sleeve for worn or damaged hub splines or sleeve fork groove and excessive clearance between sleeve and shift fork. Correct clearance is 0.008-0.018 inch.
7. Inspect synchronizer keys for wear and springs for bending.
8. Inspect reverse idler gear for worn or damaged bushing, gear teeth, or release lever coupling groove. Check for excessive clearance between sleeve and reverse lever. Correct clearance is 0.004-0.020 inch.
9. Inspect clutch housing, transaxle case, rear cover, and differential gear case for cracks or other physical damage.
10. Inspect speedometer drive gear assembly for worn or damaged teeth, 0-ring, oil seal, lip, and ring gear speedometer drive gear.