Counter Gear: Testing and Inspection

Inspection





1. Check of transmission hub sleeve No.2
(1) Check that the end of the spline gear of the transmission hub sleeve No.2 is not worn.

NOTE:
If it is worn, replace the transmission hub sleeve No.2 with a new one.

(2) Install the transmission hub sleeve No.2 to the transmission clutch hub No.2 and check that they slide smoothly.

NOTE:
If they do not slide smoothly, replace the transmission hub sleeve No.2 and the transmission clutch hub No.2 with new ones.





2. Check of transmission hub sleeve No.2 clearance
(1) Check the thickness of the gear shift fork No.2 claw.
Standard value: 7.9 to 8.0 mm {0.311 to 0.315 in}
Limit: 7.9 mm {0.311 in}

NOTE:
If the value is smaller than the limit, replace the gear shift fork No.2 with a new one.

(2) Measure the groove of the transmission hub sleeve No.2 and calculate the clearance between it and the gear shift fork No.2.
Standard value: 0.15 to 0.35 mm {0.00590 to 0.0138 in}
Limit: 0.35 mm {0.0138 in}

NOTE:
If the value exceeds the limit, replace the gear shift fork No.2 and the transmission hub sleeve No.2 with new ones as a set.





3. Check of synchronizer ring No.1
(1) Apply MG GEAR OIL SPECIAL-II to the tapered cone portion of the counter shaft 4th gear, and check the clearance between the synchronizer ring No.1 and the counter shaft 4th gear while pressing the synchronizer ring No.1 by hand.
Standard value: 0.8 to 1.6 mm {0.0314 to 0.0629 in}
Limit: 1.6 mm {0.0629 in}

CAUTION:
Check the entire circumference of the gear.

NOTE:
If the value is smaller than the limit, replace the synchronizer ring No.1 and counter shaft 4th gear with new ones.





(2) Apply MG GEAR OIL SPECIAL-II to the tapered cone portion of the counter shaft 4th gear, and check that the synchronizer ring No.1 does not slip in the circumferential direction while pressing it by hand.

NOTE:
If it slips, replace the synchronizer ring No.1 and counter shaft 4th gear with new ones.

4. Check of synchronizer ring No.3
(1) Apply MG GEAR OIL SPECIAL-II to the tapered cone portion of the counter shaft 3rd gear and the synchronizer ring set No.3, and check the clearance between the synchronizer ring set No.3 and the counter shaft 3rd gear while pressing the synchronizer ring set No.3 by hand.





Captions in illustration





Standard value





CAUTION:
Check the entire circumference of the gear.

NOTE:
If the value exceeds the limit, replace the synchronizer ring set No.3 with a new one.





(2) Apply MG GEAR OIL SPECIAL-II to the tapered cone portion of the counter shaft 3rd gear, and check that the synchronizer ring set No.3 does not slip in the circumferential direction while pressing it by hand.

NOTE:
If it slips, replace the synchronizer ring set No.3 with a new one.





5. Counter shaft check
(1) Check the outer diameter of each part.
Standard value





NOTE:
If the value is smaller than the limit, replace the counter shaft with a new one.





(2) Check the runout of the points shown in the figure.
Standard value: 0.03mm {0.00118in} or less

NOTE:
If the value is not within the limit, replace the counter shaft with a new one.





6. Check of counter shaft 3rd gear
(1) Check the inner diameter of the counter shaft 3rd gear.
Standard value: 43.015 to 43.040 mm {1.69350 to 1.69448 in}
Limit: 43.040 mm {1.69448 in}

NOTE:
If the value exceeds the limit, replace the counter shaft 3rd gear with a new one.





7. Counter shaft 4th gear check
(1) Check the inner diameter of the counter shaft 4th gear.
Standard value: 46.315 to 46.340 mm {1.82425 to 1.82441 in}
Limit: 46.340 mm {1.82441 in}

NOTE:
If the value exceeds the limit, replace the counter shaft 4th gear with a new one.





8. Check of 4th gear bearing inner race
(1) Check the outer diameter of the 4th gear bearing inner race.
Standard value: 46.225 to 46.250 mm {1.81988 to 1.82087 in}
Limit: 46.225 mm {1.81988 in}

CAUTION:
Do not measure the oil groove.

NOTE:
If the value is smaller than the limit, replace the 4th gear bearing inner race with a new one.