Output Shaft

R155F MANUAL TRANSMISSION: OUTPUT SHAFT: INSPECTION

1. INSPECT OUTPUT SHAFT





(a) Using a dial indicator, measure the circle runout of the output shaft.

Maximum circle runout:

0.03 mm (0.0012 in.)

If the circle runout is greater than the maximum, replace the output shaft with a new one.

(b) Using a micrometer, measure the outer diameter of the output shaft at A, B and C.





Standard diameter:

38.979 to 38.995 mm (1.5334 to 1.5352 in.) for A

46.984 to 47.000 mm (1.8498 to 1.8504 in.) for B

37.984 to 38.000 mm (1.4954 to 1.4961 in.) for C

Minimum diameter:

38.979 mm (1.5334 in.) for A

46.984 mm (1.8498 in.) for B

37.984 mm (1.4954 in.) for C

If the outer diameter is less than the minimum, replace the output shaft with a new one.

(c) Using a micrometer, measure the thickness of the output shaft flange as shown in the illustration.





Standard thickness:

4.8 to 5.2 mm (0.1890 to 0.2047 in.)

If the thickness is not within the specified values, replace the output shaft.

2. INSPECT 3RD GEAR





(a) Using a cylinder gauge, measure the inner diameter of the 3rd gear.

Standard diameter:

44.015 to 44.040 mm (1.7329 to 1.7339 in.)

Maximum diameter:

44.040 mm (1.7339 in.)

If the inner diameter is greater than the maximum, replace the 3rd gear with a new one.

3. INSPECT 2ND GEAR





(a) Using a cylinder gauge, measure the inner diameter of the 2nd gear.

Standard diameter:

53.015 to 53.040 mm (2.0872 to 2.0881 in.)

Maximum diameter:

53.040 mm(2.0881 in.)

If the inner diameter is greater than the maximum, replace the 2nd gear with a new one.

4. INSPECT 1ST GEAR





(a) Using a cylinder gauge, measure the inner diameter of the 1st gear.

Standard diameter:

46.015 to 46.040 mm (1.812 to 1.8126 in.)

Maximum diameter:

46.040 mm (1.8126 in.)

If the inner diameter is greater than the maximum, replace the 1st gear with a new one.

5. INSPECT 1ST GEAR THRUST WASHER





(a) Using a micrometer, measure the thickness of the 1st gear thrust washer.

Standard thickness:

5.95 to 6.05 mm (0.2346 to 0.2382 in.)

Minimum thickness:

5.96 mm (0.2346 in.)

If the thickness is out of specification, replace the 1st gear thrust washer.

6. INSPECT NO. 1 SYNCHRONIZER RING





(a) Apply gear oil to the cone of the 1st gear, and check that it does not turn in both directions while pushing the synchronizer ring No. 1 (for the 1st gear).

If it turns, replace the synchronizer ring No. 1.

(b) Measure the clearance between the synchronizer ring No. 1 and the 1st gear while pushing the synchronizer ring No. 1 to the cone of the 1st gear.





Standard clearance:

0.75 to 1.65 mm (0.0295 to 0.0649 in.)

If the clearance is not within the specified values, replace the synchronizer ring No. 1 with a new one.

7. INSPECT NO. 1 SYNCHRONIZER RING SET





(a) Apply gear oil to the cone of the 2nd gear, and check that it does not turn in both directions while pushing the synchronizer ring set No. 1 (for the 2nd synchronizer ring).

If it turns, replace the synchronizer ring set No. 1.

(b) Measure the clearance between the synchronizer ring set No. 1 (for the 2nd synchronizer ring) and 2nd gear while pushing the synchronizer ring set No. 1 to the cone of the 2nd gear.





Standard clearance:

0.65 to 1.75 mm (0.0256 to 0.0689 in.)

If the clearance is not within the specified values, replace the synchronizer ring set No. 1 (for the 2nd synchronizer ring) with a new one.

8. INSPECT NO. 2 SYNCHRONIZER RING





(a) Apply gear oil to the cone of the 3rd gear, and check that it does not turn in both directions while pushing the synchronizer ring No. 2 (for the 3rd synchronizer ring).

If it turns, replace the synchronizer ring No. 2.

(b) Check the clearance between the synchronizer ring No. 2 (for the 3rd synchronizer ring) and 3rd gear while pushing the synchronizer ring No. 2 (for the 2nd synchronizer ring) to the cone of the 3rd gear.





Standard clearance:

0.75 to 1.65 mm (0.0295 to 0.0650 in.)

If the clearance is not within the specified values, replace the synchronizer ring No. 2 (for the 3rd synchronizer ring) with a new one.

9. INSPECT REVERSE GEAR





(a) Using vernier calipers, measure the reverse gear groove and the thickness of the gear shift fork claw No. 1 clearance.

Standard clearance:

0.15 to 0.41 mm (0.0060 to 0.0161 in.)

If the clearance is not within the specified values, replace the reverse gear and the shift fork No. 1 with new ones.

10. INSPECT NO. 1 TRANSMISSION CLUTCH HUB





(a) Check that the transmission clutch hub No. 1 and reverse gear slide smoothly each other.

(b) Check the tip of the spline gear sleeve of the reverse gear for wear.

If there are any defects, replace the transmission clutch hub No. 1.

11. INSPECT NO. 2 TRANSMISSION HUB SLEEVE





(a) Using vernier calipers, measure the clearance between the transmission hub No. 2 groove and claw of the gear shift fork No. 2.

Standard clearance:

0.15 to 0.35 mm (0.0059 to 0.0138 in.)

If the clearance is not within the specified values, replace the No. 2 transmission hub sleeve No. 2 and the shift fork No. 2 with the new ones.

12. INSPECT NO. 2 TRANSMISSION CLUTCH HUB





(a) Check the sliding condition between the transmission clutch hub No. 2 and the transmission hub sleeve No. 2.

(b) Check the tip of the spline gear of the sleeve of the reverse gear for wear.