Inspection of Transmission Components

1. INSPECT OUTPUT SHAFT AND INNER RACE




a. Using calipers, measure the output shaft flange thickness.

Minimum thickness: 5.60 mm (0.2205 in.)




b. Using calipers, measure the inner race flange thickness.

Minimum thickness: 4.70 mm (0.1850 in.)




c. Using a micrometer, measure the outer diameter of the output shaft journal.

Minimum diameter:
2nd gear 42.85 mm (1.6870 in.)
3rd gear 37.80 mm (1.4882 in.)




d. Using a micrometer, measure the outer diameter of the inner race.

Minimum diameter: 42.85 mm (1.6870 in.)




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

Maximum runout: 0.06 mm (0.0024 in.)




2. CHECK OIL CLEARANCE OF FIRST GEAR
Using a dial indicator, measure the oil clearance between the gear and inner race with the needle roller bearing installed.

Standard clearance: 0.009 - 0.060 mm (0.0004 - 0.0024 in.)
Maximum clearance: 0.15 mm (0.0059 in.)

If the clearance exceeds the limit, replace the gear, inner race or needle roller bearing.




3. CHECK OIL CLEARANCE OF SECOND AND COUNTER FIFTH GEAR
Using a dial indicator, measure the oil clearance between the gear and shaft with the needle roller bearing installed.

Standard clearance:
2nd gear 0.009 - 0.060 mm (0.0004 - 0.0024 in.)
Counter 5th gear 0.009 - 0.062 mm (0.0004 - 0.0024 in.)
Maximum clearance: 0.15 mm (0.0059 in.)

If the clearance exceeds the limit, replace the gear, shaft or needle roller bearing.




4. CHECK OIL CLEARANCE OF THIRD GEAR
Using a dial indicator, measure the oil clearance between the gear and output shaft.

Standard clearance: 0.060 - 0.103 mm (0.0024 - 0.0041 in.)
Maximum clearance: 0.20 mm (0.0079 in.)

If the clearance exceeds the limit, replace the gear or output shaft.




5. INSPECT SYNCHRONIZER RINGS
a. Turn the ring and push it in to check the braking action.




b. Measure the clearance between the synchronizer ring back and gear spline end.

Standard clearance: 0.7 - 1.7 mm (0.028 - 0.067 in.)
Minimum clearance: 0.5 mm (0.020 in.)

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




6. MEASURE CLEARANCE OF SHIFT FORKS AND HUB SLEEVES
Using a feeler gauge, measure the clearance between the hub sleeve and shift fork.

Maximum clearance: 1.0 mm (0.039 in.)

If the clearance exceeds the limit, replace the shift fork or hub sleeve




7. IF NECESSARY, REPLACE INPUT SHAFT BEARING
a. Using snap ring pliers, remove the snap ring.




b. Using a press, remove the bearing.




c. Using SST and a press, install a new bearing.
SST 09506-35010







d. Select a snap ring that will allow minimum axial play and install it on the shaft.




8. IF NECESSARY, REPLACE FRONT BEARING RETAINER OIL SEAL
a. Using a screwdriver, pry out the oil seal.




b. Using SST, press in a new oil seal.
SST 09608-20012 (09608-00080, 09608-03020)

Drive in depth: 11.4 - 12.0 mm (0.449 - 0.472 in.) from retainer end

c. Coat the lip of the oil seal with MP grease.




9. IF NECESSARY, REPLACE COUNTER GEAR FRONT BEARING AND SIDE RACE
a. Using snap ring pliers, remove the snap ring.
b. Using SST and a press, press out the bearing.
SST 09950-00020




c. If necessary, remove the side race.
Using SST and a socket wrench, remove the side race.
SST 09950-20017




d. Using a 24-mm socket wrench, press in a new bearing, side race and inner race.







e. Select a snap ring that will allow minimum axial play and install it on the shaft.




10. IF NECESSARY, REPLACE COUNTER GEAR CENTER BEARING
a. Remove the bearing from the counter gear.
b. Install a new bearing on the counter gear.

NOTE: Engage the roller cages.




c. Using SST, tap out the bearing outer race.
SST 09608-35014 (09608-06020, 09608-06090)

NOTE: The outer race will be installed later as the transmission is assembled.

11. IF NECESSARY, REPLACE REVERSE RESTRICT PIN




a. Using SST, remove the screw plug.
SST 09313-30021




b. Using a pin punch and hammer drive out the slotted spring pin.
c. Replace the reverse restrict pin.
d. Using a pin punch and hammer, drive in the slotted spring pin.
e. Apply sealant to the plug threads.
Sealant: Part No.08833-00080. THREE BOND 1344, LOCTITE 242 or equivalent




f. Install and torque the screw plug.
SST 09313-30021

Torque: 250 kg-cm (18 ft-lb, 25 N-m)

12. IF NECESSARY, REPLACE REAR BEARING OUTER RACE




a. Using two screwdrivers, remove the snap ring.




b. Using SST, tap out the outer race.
SST 09608-12010 (09608-00020, 09608-00050)




c. Using SST, install a new outer race.
SST 09608-35014 (09608-06020, 09608-06100)




d. Install the snap ring.
13. REPLACE OIL SEAL ON SPEEDOMETER DRIVEN GEAR




a. Using SST, remove the oil seal.
SST 09921-00010




b. Using SST, install a new oil seal.
SST 09201-60011

Drive in depth: 25 mm (0.98 in.)

14. IF NECESSARY, REPLACE OIL SEAL




a. Using SST, remove the oil seal.
SST 09308-00010 or
09308-10010 w/ output shaft installed




b. Using SST, drive in a new oil seal.
SST 09325-20010
c. Coat the lip of the oil seal with MP grease.