Component Tests and General Diagnostics

COMPONENT PARTS INSPECTION




1. Inspect 5th gear synchronizer ring.
a. Check for wear or damage.
b. Check the braking effect of the synchronizer ring. Turn the synchronizer ring in one direction while pushing it to the gear cone. Check that the ring locks.




If the braking effect is insufficient, apply a small amount of fine lapping compound between the synchronizer ring and gear cone. Lightly rub the synchronizer ring and gear cone together.

NOTE: Ensure the fine lapping compound is completely washed off after rubbing.

c. Check again the braking effect of the synchronizer ring.
Using a feeler gauge, measure the clearance between the synchronizer ring back and gear spline end.

Minimum clearance: 0.6 mm (0.024 in.)

If the clearance is less than the minimum, replace the synchronizer ring and gear cone by applying a small amount of fine lapping compound.

NOTE: Ensure the fine lapping compound is completely washed off after rubbing.





2. Inspect shift fork and hub sleeve clearance.
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 maximum, replace the shift fork or hub sleeve.
3. Remove transaxle case receiver.
Remove the bolt and transaxle case receiver.




4. If necessary, replace input shaft front bearing and oil seal.
a. Using Special Service Tool (SST) 09612 - 65014 or equivalent, remove the bearing.




b. Using SST 09612 - 65014, remove the oil seal.




c. Using SST 09950 - 60010 (09951 - 00360), 09950-70010 (09951 -07150) and a hammer, drive in a new oil seal.

Drive in depth: 15.8 + 0.2 mm (0.622 + 0.008 in.)

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




e. Using SST 09950 - 60010 (09951 - 00460), 09950-7000 (09951-07150) and a press, install a new bearing.




5. If necessary, replace output shaft front bearing and output shaft cover.
a. Remove the bolt and bearing lock plate.
b. Using SST 09308 - 00010, pull out the bearing.
c. Remove the output shaft cover.




d. Install the output shaft cover.

NOTE: Install the output shaft cover projection into the case side hollow.





e. Using SST 09950 - 60010 (09951 - 00620), 09950- 70010 (09951 -07150) and a press, install a new bearing.
f. Install the bearing lock plate and torque the bolt.

Torque: 11 Nm (115 kgf/cm, 8 ft.lbs.)

6. Install transaxle case receiver.
Install the transaxle case receiver and torque the bolt.

Torque: 11 Nm (115 kgf/cm 8 ft lbs.)




7. If necessary, replace speedometer driven gear oil seal.
a. Using SST 09921 - 00010, remove the oil seal.
b. Using SST 09201 - 10000 (09201 - 01080), 09950-70010 (09951-07150), drive in a new oil seal.

Drive in depth: 25 mm (0.98 in.)

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




8. If necessary, replace reverse restrict pin.
a. Using a hexagon wrench, remove the straight screw plug.
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: THREE BOND 1344, LOCTITE 242 or equivalent

f. Using a hexagon wrench, install the straight screw plug.

Torque: 13 Nm (130 kgf/cm, 9 ft.lbs.)