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1. INSPECT COUNTER GEAR


A0095VKE01

  1. Using a dial indicator and 2 V-blocks, measure the shaft runout.

    Maximum runout:
    0.03 mm (0.00118 in.)

    If the runout is more than the maximum, replace the counter gear.



    A0097BIE01

  1. Using a micrometer, measure the journal diameter of each input shaft journal, at the specified positions.

    Standard Journal Diameter:
    Item
    		Specified Condition
    Journal A
    		34.002 to 34.015 (1.3387 to 1.3392)
    Journal B
    		36.985 to 37.000 (1.4561 to 1.4567)
    Journal C
    		47.985 to 48.000 (1.8892 to 1.8898)
    Journal D
    		53.985 to 54.000 (2.1254 to 2.1260)
    Journal E
    		34.002 to 34.015 (1.3387 to 1.3392)

    Minimum Journal Diameter:
    Item
    		Specified Condition
    Journal A
    		34.002 (1.3387)
    Journal B
    		36.985 (1.4561)
    Journal C
    		47.985 (1.8892)
    Journal D
    		53.985 (2.1254)
    Journal E
    		34.002 (1.3387)

    If the journal diameter is less than the minimum, replace the counter gear shaft.



2. INSPECT COUNTER SHAFT REVERSE GEAR


A0096SXE01

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

    Standard inside diameter:
    51.015 to 51.040 mm (2.0085 to 2.0095 in.)

    Maximum inside diameter:
    51.040 mm (2.0095 in.)

    If the inside diameter is more than the maximum, replace the reverse gear.



3. INSPECT COUNTER SHAFT 1ST SPEED GEAR


A0094CKE01

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

    Standard inside diameter:
    54.015 to 54.040 mm (2.1266 to 2.1276 in.)

    Maximum inside diameter:
    54.040 mm (2.1276 in.)

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



4. INSPECT COUNTER SHAFT 2ND SPEED GEAR


A009B9OE01

  1. Using a cylinder gauge, measure the inside diameter of the 2nd gear.

    Standard inside diameter:
    60.015 to 60.040 mm (2.3628 to 2.3638 in.)

    Maximum inside diameter:
    60.040 mm (2.3638 in.)

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



5. INSPECT NO. 3 TRANSMISSION HUB SLEEVE


A00967RE01

  1. Using a vernier caliper, measure the width of the No. 3 transmission hub sleeve groove (A) and the thickness of the claw part of the gear shift fork No. 4 (B), and calculate the clearance.

    Standard clearance (A - B):
    0.26 to 0.84 mm (0.0102 to 0.0331 in.)

    If the clearance is outside the specification, replace the No. 3 transmission hub sleeve and No. 4 gear shift fork.



6. INSPECT NO. 1 TRANSMISSION HUB SLEEVE


A0099WYE01

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

  1. Check that the splines of the No. 1 transmission hub sleeve are not worn.



    A0098BDE01

  1. Using a vernier caliper, measure the width of the No. 1 transmission hub sleeve groove (A) and the thickness of the claw part of the No. 1 gear shift fork (B), and calculate the clearance.

    Standard clearance (A - B):
    0.15 to 0.35 mm (0.00591 to 0.0138 in.)

    If the clearance is outside the specification, replace the No. 1 transmission hub sleeve and No. 1 gear shift fork.



7. INSPECT NO. 4 SYNCHRONIZER RING


A0096C4E01

  1. Using a feeler gauge, measure the clearance between the synchronizer ring and reverse gear.

    Standard clearance:
    0.70 to 1.50 mm (0.0276 to 0.0590 in.)

    Minimum clearance:
    0.70 mm (0.0276 in.)

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

  1. Coat the reverse gear cone with gear oil.



    A0095SZE01

  1. Check the braking effect of the synchronizer ring.

    1. Turn the synchronizer ring in both directions while pushing it against the reverse gear cone. Check that the ring locks in both directions.

      1. If No. 4 synchronizer ring turns, replace it.



8. INSPECT NO. 1 SYNCHRONIZER RING SET (for 1st Gear)


A0094UNE04

  1. Using a feeler gauge, measure the clearance between the synchronizer ring and 1st gear.

    Standard clearance:
    Inner:
    1.48 to 2.12 mm (0.0583 to 0.0835 in.)
    Middle:
    0.68 to 1.92 mm (0.0268 to 0.0756 in.)
    Outer:
    0.88 to 1.72 mm (0.0346 to 0.0677 in.)

    Minimum clearance:
    Inner:
    1.48 mm (0.0583 in.)
    Middle:
    0.68 mm (0.0268 in.)
    Outer:
    0.88 mm (0.0346 in.)
    Text in Illustration 
    *1
    		Middle
    *2
    		Outer
    *3
    		Inner

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

  1. Coat the 1st gear cone with gear oil.



    A009898E01

  1. Check the braking effect of the synchronizer ring.

    1. Turn the synchronizer ring in both directions while pushing it against the 1st gear cone. Check that the ring locks in both directions.

      1. If No. 1 synchronizer ring set turns, replace it.



9. INSPECT NO. 1 SYNCHRONIZER RING SET (for 2nd Gear)


A0094UNE04

  1. Using a feeler gauge, measure the clearance between the synchronizer ring and 2nd gear.

    Standard clearance:
    Inner:
    1.48 to 2.12 mm (0.0583 to 0.0835 in.)
    Middle:
    0.68 to 1.92 mm (0.0268 to 0.0756 in.)
    Outer:
    0.88 to 1.72 mm (0.0346 to 0.0677 in.)

    Minimum clearance:
    Inner:
    1.48 mm (0.0583 in.)
    Middle:
    0.68 mm (0.0268 in.)
    Outer:
    0.88 mm (0.0346 in.)
    Text in Illustration 
    *1
    		Middle
    *2
    		Outer
    *3
    		Inner

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

  1. Coat the 2nd gear cone with gear oil.



    A009898E01

  1. Check the braking effect of the synchronizer ring.

    1. Turn the synchronizer ring in both directions while pushing it against the 2nd gear cone. Check that the ring locks in both directions.

      1. If No. 1 synchronizer ring set turns, replace it.