Inspection

Input Shaft Inspection

Input Shaft Disassembly

- Check clearance "a" between synchronizer ring (2) and gear (1), 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 (Input shaft) (3rd and 4th)
Standard: 1.0 - 1.4 mm (0.040 - 0.055 in.)
Service limit: 0.5 mm (0.020 in.)

Key slot width "b" (3rd and 4th synchronizer ring)
Standard: 10.0 - 10.2 mm (0.394 - 0.401 in.)
Limit: 10.45 mm (0.411 in.)





- Measure width of high speed gear shift fork end "a" and groove width of high speed synchronizer sleeve "b", 5th & reverse gear shift fork end "a" and groove width of 5th speed synchronizer sleeve "b" and then calculate clearance "c" as follows:






If clearance exceeds limit, replace gear shift fork and sleeve.

Clearance "c" between fork and sleeve for high speed and 5th speed
Standard: 0.2 - 0.5 mm (0.008 - 0.020 in.)
Limit: 1.0 mm (0.039 in.)





- Check diameter of input shaft (1) and needle bush (2) as shown in figure. If measured value is out of specification, replace input shaft and/or bush.

Input shaft and needle bush specifications (diameter)










- Using "V" blocks (1) and dial gauge (2), check runout.
If runout exceeds limit below, replace input shaft (3).

Input shaft runout
Limit: 0.02 mm (0.0008 in.)





- Using cylinder gauge (1), check inside diameter of each gear. If its inside diameter exceeds specification, replace it.

Inside diameter (standard) of gear
3rd and 4th gear: 40.000 - 40.025 mm (1.5748 - 1.5757 in.)





- 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 spline portions and replace parts if excessive wear is found.