ПЕРВИЧНЫЙ ВАЛ ПРОВЕРКА

PROCEDURE

  1. INSPECT 6TH GEAR THRUST CLEARANCE

    1. Using a dial indicator, measure the 6th gear thrust clearance.

      A012FKP
      Standard Clearance
      0.15 to 0.43 mm (0.00591 to 0.0169 in.)
      Maximum Clearance
      0.43 mm (0.0169 in.)

      If the clearance exceeds the maximum, replace the No. 3 transmission clutch hub, 6th gear sub-assembly or input shaft.

  2. INSPECT 5TH GEAR THRUST CLEARANCE

    1. Using a dial indicator, measure the 5th gear thrust clearance.

      A012LM8
      Standard Clearance
      0.15 to 0.43 mm (0.00591 to 0.0169 in.)
      Maximum Clearance
      0.43 mm (0.0169 in.)

      If the clearance exceeds the maximum, replace the No. 3 transmission clutch hub, 5th gear or input shaft.

  3. INSPECT 4TH GEAR THRUST CLEARANCE

    1. Using a dial indicator, measure the 4th gear thrust clearance.

      A012JWY
      Standard Clearance
      0.15 to 0.56 mm (0.00591 to 0.0220 in.)
      Maximum Clearance
      0.56 mm (0.0220 in.)

      If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 4th gear or input shaft.

  4. INSPECT 3RD GEAR THRUST CLEARANCE

    1. Using a dial indicator, measure the 3rd gear thrust clearance.

      A012G15
      Standard Clearance
      0.15 to 0.43 mm (0.00591 to 0.0169 in.)
      Maximum Clearance
      0.43 mm (0.0169 in.)

      If the clearance exceeds the maximum, replace the No. 2 transmission clutch hub, 3rd gear or input shaft.

  5. INSPECT 6TH GEAR RADIAL CLEARANCE

    1. Using a dial indicator, measure the 6th gear radial clearance between the gear and shaft.

      A012LRT
      Standard Clearance
      0.009 to 0.045 mm (0.000354 to 0.00177 in.)
      Maximum Clearance
      0.045 mm (0.00177 in.)

      If the clearance exceeds the maximum, replace the 6th gear sub-assembly, 6th gear needle roller bearing, inner 6th gear bearing race or input shaft.

  6. INSPECT 5TH GEAR RADIAL CLEARANCE

    1. Using a dial indicator, measure the 5th gear radial clearance between the gear and shaft.

      A012MIN
      Standard Clearance
      0.009 to 0.045 mm (0.000354 to 0.00177 in.)
      Maximum Clearance
      0.045 mm (0.00177 in.)

      If the clearance exceeds the maximum, replace the 5th gear, 5th gear needle roller bearing, inner 5th gear bearing race or input shaft.

  7. INSPECT 4TH GEAR RADIAL CLEARANCE

    1. Using a dial indicator, measure the 4th gear radial clearance between the gear and shaft.

      A012H02
      Standard Clearance
      0.009 to 0.050 mm (0.000354 to 0.00197 in.)
      Maximum Clearance
      0.050 mm (0.00197 in.)

      If the clearance exceeds the maximum, replace the 4th gear, 4th gear needle roller bearing or input shaft.

  8. INSPECT 3RD GEAR RADIAL CLEARANCE

    1. Using a dial indicator, measure the 3rd gear radial clearance.

      A012FMP
      Standard Clearance
      0.009 to 0.050 mm (0.000354 to 0.00197 in.)
      Maximum Clearance
      0.050 mm (0.00197 in.)

      If the clearance exceeds the maximum, replace the 3rd gear, 3rd gear needle roller bearing or input shaft.

  9. INSPECT INPUT SHAFT

    1. Using a dial indicator, check the input shaft runout.

      A012HBA
      Maximum Runout
      0.015 mm (0.000591 in.)

      If the runout exceeds the maximum, replace the input shaft.

    2. Using a micrometer, measure the outer diameter of the input shaft journal surface at the locations indicated.

      A012MQBN04
      Standard Outer Diameter
      Location A
      25.002 to 25.017 mm (0.98432 to 0.98491 in.)
      Location B
      37.485 to 37.500 mm (1.47578 to 1.47637 in.)
      Location C
      31.690 to 31.700 mm (1.24763 to 1.24802 in.)
      Location D
      27.990 to 28.000 mm (1.10196 to 1.10236 in.)
      Minimum Outer Diameter
      Location A
      25.002 mm (0.98432 in.)
      Location B
      37.485 mm (1.47578 in.)
      Location C
      31.690 mm (1.24763 in.)
      Location D
      27.990 mm (1.10196 in.)

      If any of the outer diameters are less than the minimum, replace the input shaft.

  10. INSPECT INNER 6TH GEAR BEARING RACE

    1. Using a micrometer, measure the outer diameter of the inner 6th gear bearing race.

      A012NB4
      Standard Outer Diameter
      35.09 to 35.10 mm (1.38149 to 1.38188 in.)
      Minimum Outer Diameter
      35.09 mm (1.38149 in.)

      If the outer diameter is less than the minimum, replace the inner 6th gear bearing race.

    2. Using a cylinder gauge, measure the inside diameter of the inner 6th gear bearing race.

      A012HYI
      Standard Inside Diameter
      28.005 to 28.020 mm (1.10255 to 1.10314 in.)
      Maximum Inside Diameter
      28.020 mm (1.10314 in.)

      If the inside diameter exceeds the maximum, replace the inner 6th gear bearing race.

  11. INSPECT INNER 5TH GEAR BEARING RACE

    1. Using a micrometer, measure the outer diameter of the inner 5th gear bearing race.

      A012GW4
      Standard Outer Diameter
      37.49 to 37.50 mm (1.47598 to 1.47637 in.)
      Minimum Outer Diameter
      37.49 mm (1.47598 in.)

      If the outer diameter is less than the minimum, replace the inner 5th gear bearing race.

    2. Using a cylinder gauge, measure the inside diameter of the inner 5th gear bearing race.

      A012LFY
      Standard Inside Diameter
      31.705 to 31.720 mm (1.24822 to 1.24881 in.)
      Maximum Inside Diameter
      31.720 mm (1.24881 in.)

      If the inside diameter exceeds the maximum, replace the inner 5th gear bearing race.

  12. INSPECT 6TH GEAR SUB-ASSEMBLY

    1. Using a cylinder gauge, measure the inside diameter of the 6th gear sub-assembly.

      A012MKT
      Standard Inside Diameter
      40.109 to 40.125 mm (1.57909 to 1.57972 in.)
      Maximum Inside Diameter
      40.125 mm (1.57972 in.)

      If the inside diameter exceeds the maximum, replace the 6th gear sub-assembly.

  13. INSPECT 5TH GEAR

    1. Using a cylinder gauge, measure the inside diameter of the 5th gear.

      A012MHV
      Standard Inside Diameter
      42.509 to 42.525 mm (1.67357 to 1.67420 in.)
      Maximum Inside Diameter
      42.525 mm (1.67420 in.)

      If the inside diameter exceeds the maximum, replace the 5th gear.

  14. INSPECT 4TH GEAR

    1. Using a cylinder gauge, measure the inside diameter of the 4th gear.

      A012JKK
      Standard Inside Diameter
      42.509 to 42.525 mm (1.67357 to 1.67420 in.)
      Maximum Inside Diameter
      42.525 mm (1.67420 in.)

      If the inside diameter exceeds the maximum, replace the 4th gear.

  15. INSPECT 3RD GEAR

    1. Using a cylinder gauge, measure the inside diameter of the 3rd gear.

      A012JMT
      Standard Inside Diameter
      42.509 to 42.525 mm (1.67357 to 1.67420 in.)
      Maximum Inside Diameter
      42.525 mm (1.67420 in.)

      If the inside diameter exceeds the maximum, replace the 3rd gear.

  16. INSPECT NO. 5 SYNCHRONIZER RING

    1. Check for wear and damage.

      A012MPRC03
      *a Locks
    2. Coat the 6th gear cone with gear oil.

    3. Coat the 5th gear cone with gear oil.

    4. Turn the synchronizer ring in one direction while pushing it against the 6th gear cone.

    5. Check that the ring locks.

      If the synchronizer ring does not lock, replace the synchronizer ring.

    6. Turn the synchronizer ring in one direction while pushing it against the 5th gear cone.

    7. Check that the ring locks.

      If the synchronizer ring does not lock, replace the synchronizer ring.

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

      A012HAB
      Standard Clearance
      0.73 to 1.53 mm (0.0287 to 0.0602 in.)
      Minimum Clearance
      0.73 mm (0.0287 in.)

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

  17. INSPECT OUTER 2ND SYNCHRONIZER RING

    1. Check for wear and damage.

      A012IABC03
      *a Locks
    2. Coat the 4th gear cone with gear oil.

    3. Turn the synchronizer ring in one direction while pushing it against the 4th gear cone.

    4. Check that the ring locks.

      If the synchronizer ring does not lock, replace the synchronizer ring.

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

      A012FJP
      Standard Clearance
      0.78 to 1.58 mm (0.0307 to 0.0622 in.)
      Minimum Clearance
      0.78 mm (0.0307 in.)

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

  18. INSPECT NO. 3 SYNCHRONIZER RING

    1. Check for wear and damage.

      A012K9VC03
      *a Locks
    2. Coat the 3rd gear cone with gear oil.

    3. Turn the synchronizer ring in one direction while pushing it against the 3rd gear cone.

    4. Check that the ring locks.

      If the synchronizer ring does not lock, replace the synchronizer ring.

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

      A012N0C
      Standard Clearance
      0.78 to 1.58 mm (0.0307 to 0.0622 in.)
      Minimum Clearance
      0.78 mm (0.0307 in.)

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

  19. INSPECT NO. 2 TRANSMISSION HUB SLEEVE

    1. Check the sliding condition between the No. 2 transmission hub sleeve and the No. 2 transmission clutch hub.

      A012MI0
    2. Check that the edges of the No. 2 transmission hub sleeve splines are not worn down.

    3. Using a vernier caliper, measure the width of the No. 2 transmission hub sleeve groove (A) and the thickness of the claw part on the No. 2 gear shift fork (B), and calculate the clearance.

      A012JIYC03
      *a Clearance
      Standard Clearance (A - B)
      0.1 to 0.5 mm (0.00394 to 0.0197 in.)

      If the clearance is out of specification, replace the No. 2 transmission hub sleeve and No. 2 gear shift fork.

  20. INSPECT NO. 3 TRANSMISSION HUB SLEEVE

    1. Check the sliding condition between the No. 3 transmission hub sleeve and the No. 3 transmission clutch hub.

      A012I4R
    2. Check that the edges of the No. 3 transmission hub sleeve splines are not worn down.

    3. Using a vernier caliper, measure the width of the No. 3 transmission hub sleeve groove (A) and the thickness of the claw part on the No. 3 gear shift fork (B), and calculate the clearance.

      A012GXAC03
      *a Clearance
      Standard Clearance (A - B)
      0.1 to 0.5 mm (0.00394 to 0.0197 in.)

      If the clearance is out of specification, replace the No. 3 transmission hub sleeve and No. 3 gear shift fork.