Inspection

Inspect all parts and repair or replace as necessary.




Gears
1. Inspect the synchronizer cones for wear.
2. Inspect the gear teeth for damage, wear, and cracks.
3. Inspect the synchronizer ring matching teeth for damage and wear.




Synchronizer Ring
1. Inspect the synchronizer ring teeth for damage, wear, and cracks.
2. Inspect the tapered surface for wear and cracks.




3. Set the synchronizer ring squarely in the gear.
4. Measure the clearance between the synchronizer ring and the flank surface of the gear.

Standard clearance: 1.5 mm (0.059 in)
Minimum: 0.8 mm (0.031 in)




Clutch Hub Assembly
1. Inspect the clutch hub sleeve and hub operation.
2. Inspect the gear teeth for damage, wear, and cracks.
3. Inspect the synchronizer keys for damage, wear, and cracks.




4. Measure the clearance between the hub sleeve and shift fork.

Clearance:

Clearance




Reverse Idler Gear and Reverse Lever
1. Inspect the gear teeth for damage, wear, and cracks.
2. Measure the clearance between the reverse idler gear bushing and the reverse lever.

Standard clearance: 0.10-0.32 mm (0.004-0.013 in)
Maximum: 0.5 mm (0.020 in)




Bearing
Inspect for damage and rough rotation.




Primary Shaft Gear and Secondary Shaft Gear
1. Inspect the gear contact surface for damage and wear.
2. Inspect the splines for damage and wear.
3. Inspect the gear teeth for damage, wear, and cracks.
4. Inspect the oil passage for clogging.
5. Measure the shaft gear runout.

Primary shaft gear runout: 0.05 mm (0.002 in) max.

Secondary shaft gear runout: 0.015 mm (0.0006 in) max.




6. If the shaft gear is replaced, adjust the bearing preload.







7. Determine the clearance between the shaft gears and the gears.

Clearance:

Clearance




Speedometer Sensor (Speedometer Driven Gear)
1. Inspect the teeth for damage and wear.
2. Inspect the O-ring for damage and wear.