Inspection of Output Shaft Assembly

1. MEASURE EACH GEAR THRUST CLEARANCE




a. Using a feeler gauge, measure the thrust clearance of 1st gear and 3rd gear.




b. Using a dial indicator, measure the thrust clearance of 2nd gear.

1st gear
Standard clearance: 0.10 - 0.45 mm (0.0039 - 0.0177 in.)
Maximum clearance: 0.50 mm (0.0197 in.)

2nd and 3rd gear
Standard clearance: 0.10 - 0.25 mm (0.0039 - 0.0098 in.)
Maximum clearance: 0.30 mm (0.0118 in.)




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

1st gear
Standard clearance: 0.020 - 0.073 mm (0.0008 - 0.0029 in.)
Maximum clearance: 0.16 mm (0.0063 in.)

2nd and 3rd gear
Standard clearance: 0.015 - 0.068 mm (0.0006 - 0.0027 in.)
Maximum clearance: 0.16 mm (0.0063 in.)

If the clearance exceeds the limit, replace the gear, needle roller bearing or shaft.
3. INSPECT OUTPUT SHAFT




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

Minimum thickness: 4.70 mm (0.1850 in.)




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

Minimum diameter:
A 1st gear 38.860 mm (1.5299 in.)
B 2nd gear 46.860 mm (1.8449 in.)
C 3rd gear 37.860 mm (1.4905 in.)




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

Maximum runout: 0.06 mm (0.0024 in.)

4. 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 the gear spline end.

Standard clearance: 0.8 - 1.6 mm (0.031 - 0.063 in.)
Minimum clearance: 0.6 mm (0.024 in.)

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




5. 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.