Transmission Unit

R155 MANUAL TRANSMISSION: MANUAL TRANSMISSION UNIT: INSPECTION

1. INSPECT NO. 3 SYNCHRONIZER RING OUTER





(a) Apply gear oil to the cone part of gear spline piece No. 5, and check that it does not turn in both directions while pushing the synchronizer ring outer No. 3 to the gear spline piece No. 5.

If it turns, replace the synchronizer ring.

(b) Measure the clearance between the synchronizer ring outer No. 3 and gear spline piece No. 5 while pushing the synchronizer ring outer No. 3 to the cone part of the gear spline piece No. 5.





Standard clearance:

0.68 to 1.32 mm (0.0267 to 0.0610 in.)

If the clearance is not within the specified values, replace synchronizer ring outer No. 3 with a new one.

2. INSPECT NO. 3 TRANSMISSION HUB SLEEVE





(a) Check that the counter shaft 5th gear and transmission hub sleeve No. 3 slide smoothly each other.

(b) Check the tip of the spline gear of the transmission hub sleeve No. 3 for wear.

If there are any detects, replace the transmission hub sleeve No. 3.

(c) Using vernier calipers, measure the transmission hub sleeve No. 3 groove and the thickness of the claw part of the shift fork No. 3 to calculate the clearance.





Standard clearance:

0.26 to 0.84 mm (0.0102 to 0.0331 in.)

If the clearance is not within the specified values, replace the transmission hub sleeve No. 3 and shift fork No. 3 with new ones.

3. INSPECT COUNTERSHAFT 5TH GEAR





(a) Using a cylinder gauge, measure the inner diameter of the counter 5th gear.

Standard diameter:

38.015 to 38.040 mm (1.4967 to 1.4976 in.)

Maximum diameter:

38.040 mm (1.4976 in.)

If the diameter greater than the maximum, replace the counter shaft 5th gear with a new one.

4. INSPECT REVERSE IDLER GEAR SUB-ASSY





(a) Using a caliper gauge, measure the inner diameter of the reverse idler gear.

Standard diameter:

24.040 to 24.061 mm (0.9465 to 0.9473 in.)

Maximum diameter:

24.061 mm (0.9473 in.)

If the clearance is greater than the maximum, replace the reverse idler gear with a new one.

(b) Using a micrometer, measure the outer diameter of the sliding part of the reverse idler gear on the reverse idler gear shaft.

Standard diameter:

23.979 to 24.000 mm (0.9441 to 0.9449 in.)

Minimum diameter:

23.979 mm (0.9441 in.)

If the diameter is outside the specification, replace the reverse idler gear shaft with a new one.

(c) Subtract the reverse idler gear shaft inside diameter measurement from the reverse idler gear diameter clearance.

Standard clearance:

0.040 to 0.082 mm (0.0016 to 0.0032 in.)

If the clearance is not as specified, replace the reverse idler gear or reverse idler gear shaft.

(d) Using a feeler gauge, measure the thrust clearance of the shoe part between the reverse idler gear and the reverse shift arm.





Standard clearance:

0.05 to 0.35 mm (0.0020 to 0.0138 in.)

If the clearance is outside the specification, replace the idler gear and reverse shift arm with new ones.