Counter Shaft and Main Shaft Inner Parts

COUNTER SHAFT AND MAIN SHAFT INNER PARTS





^ Check tooth surface of gear and rotation of bearing and replace with new one if necessary. As long as no abnormal condition such as noise exists before removal, replacement is unnecessary.








^ Inspect needle bearings and needle contacting surfaces (rotating surfaces) and replace with new ones as required.

NOTE: Should abnormal noise be heard before disassembly, it is necessary to carefully check needle contacting surface inside of each gear besides those parts shown in the figure.





^ Check clearance "a" between synchronizer ring and gear, key slot width "b" in synchronizer ring and each chamfered tooth of gear and synchronizer ring and replace with new one, if necessary. Also, check gear tooth.
Clearance "a" between synchronizer ring and gear:
Standard: 1.0 - 1.4 mm (0.039 - 0.055 inch)
Service limit: 0.5 mm (0.019 inch)
Key slot width "b":
Standard: 10.1 mm (0.397 inch)
Service limit: 10.4 mm (0.409 inch)





^ Using feeler gauge, check clearance between sleeve (1) and shifter fork (2) and replace parts if necessary.
Clearance "c" between sleeve and shifter fork: Maximum 1.0 mm (0.039 inch)
^ Check chamfered part of each sleeve for damage and excessive wear, and replace as necessary.
^ Check each synchronizer key and synchronizer spring and replace as necessary.
^ Check splined portions and replace parts if excessive wear are found.