With G52 Transmission

1. INSPECT OUTPUT SHAFT AND INNER RACE
(a) Using calipers, measure the output shaft flange thickness.
Minimum thickness: 4.80 mm (0.1890 in.)

(b) Using calipers, measure the inner race flange thickness.
Minimum thickness: 3.99 mm (0.1571 in.)

(c) Using a micrometer, measure the outer diameter of the output shaft journal.
Minimum diameter:
2nd gear 37.984 mm (1.4954 in.)
3rd gear 34.984 mm (1.3773 in.)

(d) Using a micrometer, measure the outer diameter of the inner race.
Minimum diameter: 38.985 mm (1.5348 in.)

(e) Using a dial indicator, check the shaft runout.
Maximum runout: 0.05 mm (0.0020 in.)

2. CHECK OIL CLEARANCE OF FIRST GEAR
Using a dial indicator, measure the oil clearance between the gear and inner race with the needle roller bearing installed.
Standard clearance:
0.009 - 0.032 mm (0.0004 - 0.0013 in.)
Maximum clearance:
0.032 mm (0.0013 in.)
If the clearance exceeds the limit, replace the gear, inner race or needle roller bearing.

3. CHECK OIL CLEARANCE OF SECOND, THIRD AND COUNTER FIFTH GEARS
Using a dial indicator, measure the oil clearance between the gear and shaft with the needle roller bearing installed.
Standard clearance:
2nd and 3rd gears
0.009 - 0.033 mm (0.0004 - 0.0013 in.)
Counter 5th gear
0.009 - 0.032 mm (0.0004 - 0.0013 in.)
Maximum clearance:
2nd and 3rd gears
0.033 mm (0.0013 in.)
Counter 5th gear
0.032 mm (0.0013 in.)
If the clearance exceeds the limit, replace the gear, needle roller bearing or shaft.

4. INSPECT SYNCHRONIZER RINGS
(a) Turn the ring and push it in to check the braking action.

(b) Measure the clearance between the synchronizer ring back and the gear spline end.
Standard clearance:
1.0 - 2.0 mm (0.039 - 0.079 in.)
Minimum clearance:
0.8 mm (0.031 in.)
If the clearance is less than the limit, replace the synchronizer ring.

5. MEASURE CLEARANCE OF SHIFT FORKS AND HUB SLEEVES
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.
Maximum clearance: 1.0 mm (0.039 in.)
If the clearance exceeds the limit, replace the shift fork or hub sleeve.

6. IF NECESSARY, REPLACE INPUT SHAFT BEARING
(a) Using snap ring pliers, remove the snap ring.

(b) Using a press, remove the bearing.

(d) Select a snap ring that will allow minimum axial play and install it on the shaft.

7. IF NECESSARY, REPLACE FRONT BEARING RETAINER OIL SEAL
(a) Using a screwdriver, pry out the oil seal.

(b) Using SST, press in a new oil seal.
SST 09223-50010
Drive in depth:
12.2 - 13.2 mm (0.480 - 0.520 in.)
Transmission case installation surface

8. IF NECESSARY, REPLACE COUNTER GEAR FRONT BEARING
(a) Using snap ring pliers, remove the snap ring.
(b) Using SST, press out the bearing.
SST 09950-00020
(c) Replace the side race.

(d) Using a socket wrench, press in the bearing, side race and inner race.

(e) Select a snap ring that will allow minimum axial play and install it on the shaft.

9. IF NECESSARY, REPLACE REVERSE RESTRICT PIN
(a) Using a torx socket wrench, remove the screw plug.

(b) Using a pin punch and hammer, drive out the slotted spring pin.
(c) Pull off the lever housing and slide out the shaft.
(d) Install the lever housing.
(e) Using a pin punch and hammer, drive in the slotted spring pin.
(f) Apply liquid sealer to the plug threads.
Sealant:
Part No.08833-00080, THREE BOND 1344, LOCTITE 242 or equivalent

(g) Using a torx socket wrench, install and torque the screw plug.
Torque: 190 kg-cm (14 ft-lb, 19 N-m)

10. IF NECESSARY, REPLACE OIL SEAL
(a) Using a screwdriver, pry out the oil seal.

(b) Using SST, drive in a new oil seal.
SST 09325-12010