Output Shaft: Inspection

1. Using a V-block and a dial indicator, inspect the shaft for runout.

   Maximum runout: 

   0.03 mm (0.0012 in.) 

   If the runout is greater than the maximum, replace the output shaft.

   Fig 1: Inspecting Output Shaft For Runout

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2. Using a micrometer, measure the outside diameter of the output shaft journal surface.

Standard outside diameter 

Minimum outside diameter 

If the outside diameter is less than the minimum, replace the output shaft.

Fig 2: Measuring Outside Diameter Of Output Shaft Journal Surface

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1. Using a cylinder gauge, measure the inside diameter.

   Standard inside diameter: 

   50.009 to 50.025 mm (1.9689 to 50.025 in.) 

   Maximum inside diameter: 

   50.025 mm (1.9695 in.) 

   If the inside diameter is greater than the maximum, replace the 2nd gear.

Fig 3: Measuring Inside Diameter

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1. Using a cylinder gauge, measure the inside diameter.

   Standard inside diameter: 

   51.009 to 51.025 mm (51.009 to 51.0525 in.) 

   Maximum inside diameter: 

   51.025 mm (2.0089 in.) 

   If the inside diameter is greater than the maximum, replace the 1st gear.

Fig 4: Measuring Inside Diameter

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1. Coat the 2nd gear cone with gear oil. Turn the No. 2 synchronizer ring set in one direction while pushing it against the No. 2 synchronizer ring set. Check that the ring locks.

   If the No. 2 synchronizer ring set does not lock, replace the synchronizer ring or 2nd gear.

   Fig 5: Inspecting No. 2 Synchronizer Ring Set

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2. Check the clearance between the No. 2 synchronizer ring set and 2nd gear while pushing the 2nd gear against the No. 2 synchronizer ring set.

   Standard clearance: 

   0.70 to 1.45 mm (0.0276 to 0.0571 in.) 

   If the clearance is out of specification, replace the No. 2 synchronizer ring set with a new one.

Fig 6: Checking Clearance Between No. 2 Synchronizer Ring Set And 2nd Gear

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1. Coat the 1st gear cone with gear oil. Turn the No. 1 synchronizer ring set in one direction while pushing it against the 1st gear cone. Check that the ring locks.

   If the No. 1 synchronizer ring set does not lock, replace it with a new one.

   Fig 7: Inspecting No. 1 Synchronizer Ring Set

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2. Check the clearance between the No. 1 synchronizer ring set and 1st gear while pushing the 1st gear against the cone of the No. 1 synchronizer ring set.

   Standard clearance: 

   0.70 to 1.45 mm (0.0276 to 0.0571 in.) 

   If the clearance is out of specification, replace the No. 1 synchronizer ring set with a new one.

Fig 8: Checking Clearance Between No. 1 Synchronizer Ring Set And 1st Gear

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1. Using vernier calipers, measure the width of the reverse gear groove (A) and thickness of the claw part on the No. 1 gear shift fork (B), and calculate the clearance.

   Standard clearance: 

   A - B = 0.15 to 0.35 mm (0.0276 to 0.0571 in.) 

   If the clearance is out of specification, replace the reverse gear and No. 1 gear shift fork with new ones.

Fig 9: Measuring Width Of Reverse Gear Groove

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1. Check the sliding condition between the No. 1 transmission clutch hub and the reverse gear.
2. Check the tip of the spline gear on the sleeve of the reverse gear for wear.

   If any defects are found, replace the reverse gear or the No. 1 transmission clutch hub.

Fig 10: Inspecting No. 1 Transmission Clutch Hub

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