Component Tests and General Diagnostics

Inspection





1. Gear shift head No.1 check
(1) Check the dimension of the gear shift head No.1 groove.
Standard value: 15.2 to 15.4 mm {0.59843 to 0.60630 in}
Limit: 15.4 mm {0.60630 in}

NOTE:
If the value exceeds the limit, replace the gear shift head No.1 with a new one.





2. Gear shift head No.2 check
(1) Check the dimension of the gear shift head No.2 groove.
Standard value: 15.2 to 15.4 mm {0.59843 to 0.60630 in}
Limit: 15.4 mm {0.60630 in}

NOTE:
If the value exceeds the limit, replace the gear shift head No.2 with a new one.





3. Gear shift head No.3 check
(1) Check the dimension of the gear shift head No.3 groove.
Standard value: 15.2 to 15.4 mm {0.59843 to 0.60630 in}
Limit: 15.4 mm {0.60630 in}

NOTE:
If the value exceeds the limit, replace the gear shift head No.3 with a new one.





4. Shift shaft check
(1) Check the thickness of the shift shaft claw.
Standard value: 14.8 to 15.0 mm {0.583 to 0.591 in}
Limit: 14.8 mm {0.583 in}

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





5. Check of shift inner lock block No.1.
(1) Check the thickness of the shift inner lock block No.1 claw.
Standard value: 14.8 to 15.0 mm {0.583 to 0.591 in}
Limit: 14.8 mm {0.583 in}

NOTE:
If the value is smaller than the limit, replace the shift inner lock block No.1 with a new one.





6. Gear shift fork No.4 check
(1) Check the dimension of the gear shift fork No.4 groove.
Standard value: 15.2 to 15.4 mm {0.59843 to 0.60630 in}
Limit: 15.4 mm {0.60630 in}

NOTE:
If the value exceeds the limit, replace the gear shift fork No.4 with a new one.





7. Check of 5th shift head
(1) Check the dimension of the 5th shift head groove.
Standard value: 15.2 to 15.4 mm {0.59843 to 0.60630 in}
Limit: 15.4 mm {0.60630 in}

NOTE:
If the value exceeds the limit, replace the 5th shift head with a new one.





8. Check of synchronizer ring No.2
(1) Apply MG GEAR OIL SPECIAL-II to the tapered cone portion of the counter shaft 6th gear. With the synchronizer ring No.2 pressed by hand, check the clearance between the synchronizer ring No.2 and the counter shaft 6th gear.
Standard value: 0.88 to 1.52 mm {0.0346 to 0.0598 in}
Limit: 1.52 mm {0.0598 in}

CAUTION:
Check the entire circumference of the gear.

NOTE:
If the value is smaller than the limit, replace the synchronizer ring No.2 and the counter shaft 6th gear with new ones.





(2) Apply MG GEAR OIL SPECIAL-II to the tapered cone portion of the counter shaft 6th gear, and check that the synchronizer ring No.2 does not slip in the circumferential direction while pressing it by hand.

NOTE:
If it slips, replace the synchronizer ring No.2 and the counter shaft 6th gear with new ones.





9. Check of counter shaft 6th gear
(1) Check the inner diameter of the counter shaft 6th gear.
Standard value: 34.015 to 34.040 mm {1.33917 to 1.34016 in}
Limit: 34.040 mm {1.34016 in}

NOTE:
If the value exceeds the limit, replace the counter shaft 6th gear with a new one.





10. Check of transmission hub sleeve No.4
(1) Check that the end of the spline gear of the transmission hub sleeve No.4 is not worn.

NOTE:
If it is worn, replace the transmission hub sleeve No.4 with a new one.

(2) Install the transmission hub sleeve No.4 to the transmission clutch hub No.4 and check that they slide smoothly.

NOTE:
If they do not slide smoothly, replace the transmission hub sleeve No.4 and the transmission clutch hub No.4 with new ones.





11. Check of transmission hub sleeve No.4 clearance
(1) Check the thickness of the gear shift fork No.4 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.4 with a new one.

(2) Measure the groove of the transmission hub sleeve No.4 and calculate the clearance between it and the gear shift fork No.4.
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.4 and the transmission hub sleeve No.4 with new ones as a set.





12. Reverse idler gear check
(1) Check the inner diameter of the reverse idler gear.
Standard value: 22.040 to 22.061mm {0.86771 to 0.86854 in}
Limit: 22.061mm {0.86854 in}

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





13. Reverse idler gear shaft check
(1) Check the outer diameter of the reverse idler gear shaft.
Standard value: 21.979 to 22.000 mm {0.86531 to 0.86614 in}
Limit: 21.979 mm {0.86531 in}

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