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.

End play "L" : Baulk Ring Clearance

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.

Bulk Ring and Spread Spring





- Check the cam surface and contact surface of the bulk ring for damage and uneven wear. Replace if necessary.
- Check the spread springs for damage. Replace if necessary.

Bulk Ring Clearance for Single Cone Synchronizer (6th)





Measure the clearance "A" when pressing the bulk 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" : Baulk Ring Clearance

Bulk Ring Clearance for Triple Cone Synchronizer (1st and 2nd)





Measure the clearance of outer bulk ring (1), synchronizer cone (2), and inner bulk ring (3) with the following procedure.

CAUTION:
The outer bulk ring, synchronizer cone, and inner bulk 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 bulk 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" : Baulk Ring Clearance










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" : Baulk Ring Clearance










3. Measure the clearance "C" when pressing the outer bulk 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 "A" : Baulk Ring Clearance


Bearing





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