Output Shaft: Inspection

1. Check for wear or damage.
2. Check the braking effect of the synchronizer ring.

   Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.

   If it does not lock, replace the synchronizer ring.

   Fig 1: Inspecting Gear Synchronizer Rings

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3. Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.

   Minimum clearance: 0.7 mm (0.028 in.) 

   If the clearance is less than the minimum, replace the synchronizer ring.

   Fig 2: Measuring Clearance Between Synchronizer Ring Back & Gear Spline End

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Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.

Maximum clearance: 0.35 mm (0.0138 in.) 

If the clearance exceeds the maximum, replace the shift fork or hub sleeve.

Fig 3: Measuring No. 1 Shift Fork And Hub Sleeve Clearance

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1. Check the output shaft for wear or damage.
2. Using a micrometer, measure the outer diameter of the output shaft journal surface.

   Minimum outer diameter: 

   Part A: 37.610 mm (1.4807 in.) 

   Part B: 34.502 mm (1.3583 in.) 

   Fig 4: Measuring Outer Diameter Of Output Shaft Journal Surface

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3. Using a dial indicator, check the shaft runout.

   Maximum runout: 0.03 mm (0.0012 in.) 

   Fig 5: Checking Shaft Runout

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