Output Shaft: Testing and Inspection

Inspection





1. Check of output shaft bearing RR
(1) Check the output shaft bearing RR.
Criteria: There is no abnormal response, bind, noise, and play.

NOTE:
If defective, replace the output shaft bearing RR with a new one.





2. Output shaft check
(1) Check the outer diameter of each part.
Standard value





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





(2) Check the runout at 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 output shaft with a new one.





3. Reverse gear check
(1) Check the inner diameter of the reverse gear.
Standard value: 47.015 to 47.040 mm {1.85098 to 1.85197 in}
Limit: 47.040 mm {1.85197 in}

NOTE:
If the value exceeds the limit, replace the reverse gear with a new one.





4. 1st gear check
(1) Check the inner diameter of the 1st 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 1st gear with a new one.





5. 2nd gear check
(1) Check the inner diameter of the 2nd gear.
Standard value: 49.015 to 49.040 mm {1.92972 to 1.93071 in}
Limit: 49.040 mm {1.93071 in}

NOTE:
If the value exceeds the limit, replace the 2nd gear with a new one.





6. Check of 1st gear bearing inner race
(1) Check the outer diameter of the 1st gear bearing inner race.
Standard value: 40.284 to 40.300 mm {1.58598 to 1.58661 in}
Limit: 40.284 mm {1.58598 in}

NOTE:
If the value is smaller than the limit, replace the 1st gear bearing inner race with a new one.





7. Check of transmission hub sleeve No.1 clearance
(1) Check the thickness of the gear shift fork No.1 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.1 with a new one.

(2) Measure the groove of the transmission hub sleeve No.1 and calculate the clearance between it and the gear shift fork No.1.
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.1 and the transmission hub sleeve No.1 with new ones as a set.





8. Check of transmission hub sleeve No.3 clearance
(1) Check the thickness of the gear shift fork No.3 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.3 with a new one.

(2) Measure the groove of the transmission hub sleeve No.3 and calculate the clearance between it and the gear shift fork No.3.
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.3 and the transmission hub sleeve No.3 with new ones as a set.





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

NOTE:
If it is worn, replace the transmission hub sleeve No.1 with a new one.
(2) Install the transmission hub sleeve No.1 to the transmission clutch hub No.1 and check that they slide smoothly.

NOTE:
If they do not slide smoothly, replace the transmission hub sleeve No.1 and the transmission clutch hub No.1 with new ones.





10. Check of transmission hub sleeve No.3
(1) Check that the end of the spline gear of the transmission hub sleeve No.3 is not worn.

NOTE:
If it is worn, replace the transmission hub sleeve No.3 with a new one.

(2) Install the transmission hub sleeve No.3 to the transmission clutch hub No.3 and check that they slide smoothly.

NOTE:
If they do not slide smoothly, replace the transmission hub sleeve No.3 and the transmission clutch hub No.3 with new ones.

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





Captions in illustration





Standard value





CAUTION:
Check the entire circumference of the gear.

NOTE:
If the value is not within the standard value, replace the synchronizer ring set No.1 with a new one.





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

NOTE:
If it slips, replace the synchronizer ring set No.1 with a new one.

12. Check of synchronizer ring set No.1 (for 2nd gear)
(1) Apply MG GEAR OIL SPECIAL-II to the tapered cone portion of the 2nd gear and the synchronizer ring set No.1, and check the clearance between the synchronizer ring set No.1 and the 2nd gear while pressing the synchronizer ring set No.1 by hand.





Captions in illustration





Standard value





CAUTION:
Check the entire circumference of the gear.

NOTE:
If the value is not within the standard value, replace the synchronizer ring set No.1 with a new one.





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

NOTE:
If it slips, replace the synchronizer ring set No.1 with a new one.