Inspection

MAINSHAFT AND GEAR


Inspection


INSPECTION BEFORE DISASSEMBLY

Shaft
Before disassembly, measure the end play "L". If the end play is outside the standard value, disassemble and inspect.






1 : Snap ring
2 : 5th-6th synchronizer hub


End play "L" : Refer to End Play.


INSPECTION AFTER DISASSEMBLY

Shaft and Gear
- Check the shaft for damage or bend. Replace if necessary.





- Check the gears for any damage, scaling, or uneven wear.
Replace if necessary.

Synchronizer Hub and Coupling Sleeve
- Check the contact surface of the coupling sleeve, synchronizer hub, and shifting inserts for damage and uneven wear. Replace if necessary.





- The coupling sleeve and synchronizer hub moves smoothly.

Baulk Ring and Spread Spring
- Check the cam surface and contact surface of the baulk ring for damage and uneven wear. Replace if necessary.





- Check the spread springs for damage. Replace if necessary.

Baulk Ring Clearance for Single Cone Synchronizer (6th)
Measure the clearance "A" when pressing the baulk ring (1) against the cone (B) of clutch gear by hands at 2 points or more on the opposite side using a feeler gauge (C), and then calculate the mean value. Replace if outside the limit value.






Clearance "A" : Refer to Baulk Ring Clearance.


Baulk Ring Clearance for Triple Cone Synchronizer (1st and 2nd)
Measure the clearance of outer baulk ring (1), synchronizer cone (2), and inner baulk ring (3) with the following procedure.






CAUTION:
The outer baulk ring, synchronizer cone, and inner baulk ring manage the clearances "A", "B", and "C" as a set. Therefore, replace them as a set if the clearances are outside the limit value.
1. Measure the clearance "A" when pressing the outer baulk ring






2 : Synchronizer cone
3 : Inner baulk ring

(1) against the cone (C) of clutch gear by hands at 2 points or more on the opposite side using a feeler gauge (B), and then calculate the mean value.

Clearance "A" : Refer to Baulk Ring Clearance.







1 : Outer baulk ring
2 : Synchronizer cone

2. Measure the clearance "B" at 2 points or more on the opposite side using a feeler gauge (A), and then calculate the mean value.


Clearance "B" : Refer to Baulk Ring Clearance.







2 : Synchronizer cone
3 : Inner baulk ring

3. Measure the clearance "C" when pressing the outer baulk ring
(1) against the cone (B) of clutch gear by hands at 2 points or more on the opposite side using a feeler gauge (A), and then calculate the mean value.

Clearance "C" : Refer to Baulk Ring Clearance.






Bearing
Check the bearing for damage and unsmooth rotation. Replace if necessary.