2. Transaxle Inspection Procedure

Transaxle Inspection Procedure

^ Tools Required
- J 26900-2 Micrometer
- J 8001 Dial Indicator
- J 26900-13 Magnetic Base





1. Using a dial indicator, measure the thrust clearance of 6th gear.

Thrust Clearance
Standard thrust clearance should be between 0.10 - 0.60 mm (0.0039 - 0.0236 inch). Maximum clearance should not exceed 0.60 mm (0.0236 inch).





2. Using a dial indicator, measure the radial runout of 6th gear.

Thrust Clearance
Standard radial runout should be between 0.009 - 0.50 mm (0.0003 - 0.0020 inch). Maximum runout should not exceed 0.50 mm (0.0020 inch).
3. If the gear exceeds any of the maximum measurements, replace the gear, roller bearing or shaft.





4. Using a dial indicator, measure the thrust clearance of 5th gear.

Thrust Clearance
Standard thrust clearance should be between 0.10 - 0.62 mm (0.0039 - 0.0244 inch). Maximum clearance should not exceed 0.62 mm (0.0244 inch).
5. Using a dial indicator, measure the radial runout of 5th gear.

Thrust Clearance
Standard radial runout should be between 0.015 - 0.056 mm (0.0006 - 0.0022 inch). Maximum runout should not exceed 0.56 mm (0.0022 inch).





6. If the gear exceeds any of the maximum measurements, replace the gear, roller bearing or shaft.





7. Using a feeler gage, measure the thrust clearance for 3rd and 4th gears of the input shaft.

Standard Clearance
3rd gear: 0.10 - 0.35 mm (0.0039 - 0.0138 inch).
4th gear: 0.10 - 0.55 mm (0.0039 - 0.0217 inch).





8. Using a dial indicator, measure the radial clearance between the gears and the shaft.

Standard Clearance
3rd and 4th gear radial clearance: 0.15 - 0.58 mm (0.0006 - 0.0023 inch).
9. If the clearance exceeds the maximum measurement, replace the gear, roller bearing or shaft.





10. Check the 3rd and 4th gear braking action of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it into the gear cone. Ensure that the ring locks. Replace the ring if necessary.





11. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end. 3rd gear minimum clearance is 0.65 mm (0.0256 inch). 4th gear minimum clearance is 0.75 mm (0.0295 inch). If the clearance is less than the minimum, replace the synchronizer ring.





12. Using a feeler gage, measure the clearance between the hub sleeve and the gear shift fork. Maximum clearance is 0.35 mm (0.014 inch). If the clearance exceeds the maximum, replace the gear shift fork or hub sleeve.





13. Using a micrometer, measure the outer diameter of the input shaft journal surfaces.

Minimum Outer Diameter
^ A: 21.991 mm (0.8658 inch)
^ B: 24.885 mm (0.9797 inch)
^ C: 28.985 mm (1.1411 inch)
^ D: 30.985 mm (1.2199 inch)
^ E: 24.985 mm (0.9837 inch)
14. If the out diameter is less than the minimum, replace the input shaft.





15. Using a dial indicator, check the output shaft journals for runout. Maximum runout is 0.03 mm (0.0012 inch).
16. If the runout exceeds the maximum, replace the output shaft.





17. Using a feeler gage, measure the thrust clearance for 1st and 2nd gears of the output shaft.

Standard Clearance
1st gear: 0.10 - 0.40 mm (0.0039-0.0157 inch).
2nd gear: 0.10 - 0.55 mm (0.0039 - 0.0217 inch).





18. Using a dial indicator, measure the radial clearance between the gears and the shaft.

Standard Clearance
1st and 2nd gear radial clearance: 0.15 - 0.58 mm (0.0006 - 0.0023 inch).
19. If the clearance exceeds the maximum measurement, replace the gear, roller bearing or shaft.





20. Check the 1st gear braking action of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it into the gear cone. Ensure that the ring locks. Replace the ring if necessary.





21. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end. Minimum clearance is 0.75 mm (0.0295 inch). If the clearance is less than the minimum, replace the synchronizer ring.





22. Check the 2nd gear braking action of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it into the gear cone. Ensure that the ring locks. Replace the ring if necessary.





23. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end. Minimum clearance is 0.70 mm (0.0276 inch). If the clearance is less than the minimum, replace the synchronizer ring.





24. Using a feeler gage, measure the clearance between the hub sleeve and the gear shift fork. Maximum clearance is 0.35 mm (0.014 inch). If the clearance exceeds the maximum, replace the gear shift fork or hub sleeve.





25. Using a micrometer, measure the outer diameter of the input shaft journal surfaces.

Minimum Outer Diameter
^ 1: 31.985 mm (1.2592 inch)
^ 2: 37.985 mm (1.4955 inch)
^ 3: 32.985 mm (1.2986 inch)
26. If the out diameter is less than the minimum, replace the output shaft.





27. Using a dial indicator, check the output shaft journals for runout. maximum runout is 0.03 mm (0.0012 inch).
28. If the runout exceeds the maximum, replace the output shaft.