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 and 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 output shaft with the needle roller bearing installed.

Standard clearance:

(0.0004 - 0.0024 In.) Maximum clearance: 0.15 mm (0.0059 in.)

If the clearance exceeds the limit, replace the gear, output shaft and 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 and 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 the gear spline end.

(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.

Mark

Thickness

mm (in.)

1

2.05 -

2.10

(0.0807

- 0.0827)

2

2.10 -

2.15

(0.0827

- 0.0846)

3

2.15 -

2.20

(0.0846

- 0.0866)

4

2.20 -

2.25

(0.0866

- 0.0886)

5

2.25 -

2.30

(0.0886

- 0.0906)

11

2.30 -

2.35

(0.0906

- 0.0925)

12

2.35 -

2.40

(0.0925

- 0.0945)

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.

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 a press and SST, 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.

SST 09608-20012 (09608-03020, 09608-00080)

Oil seal depth: 11.4 — 12.0 mm from retainer end (0.449 - 0.472 in.)

9. IF NECESSARY. REPLACE COUNTER GEAR FRONT BEARING AND SIDE RACE

(a) Using snap ring pliers, remove the snap ring.

(b) Using a press and SST, press out the bearing. SST 09950-00020

(c) Check the side race for wear or damage.

(d) If necessary, remove the side race.

Using a SST and socket wrench, remove the side race. SST 09950-20016

(e) Using a socket wrench, press in a new bearing, side race and inner race.

«moo 19

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

Mark

Thickness

mm (in.)

1

2.05 -

2.10

(0.0807

- 0.08271

2

2.10 -

2.15

(0.0827

- 0.0846)

3

2.15 -

2.20

(0.0846

- 0.0866)

4

2.20 -

2.25

(0.0866

- 0.0886)

5

2.25 -

2.30

(0.0886

- 0.0906)

6

2.30 -

2.35

(0.0906

- 0.0925)

7

2.35 -

2.40

(0.0925

0.0945)

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) Pull off the lever housing and slide out the shaft.

(d) Install the lever housing.

(e) Using a pin punch and hammer, drive in the slotted spring pin.

(f) Apply liquid sealer to the plug.

(g) Install and torque the screw plug. Torque: 250 kg-cm (18 ft-lb, 25 N m)

12. IF NECESSARY, REPLACE REAR BEARING OUTER RACE

(a) Remove the outer race from the extension housing. (1) Using two screwdrivers, remove the snap ring.

(2) Using SSTf tap out the outer race. SST 09608-35014 [09608-06020, 09608-06090)

(b) Install the bearing outer race.

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

(2) Install the snap ring.

__.r

25mm nrJJiui

SST

mvoic0

13. REPLACE OIL SEAL ON SPEEDOMETER DRIVEN GEAR

la) Using SST, remove the oil seal. SST 09921 00010

(b) Using SST, install a new oil seal.

SST 09201-60011

14. IF NECESSARY, REPLACE OIL SEAL AND BUSHING

(a) Using SST, remove the oil seal.

SST 09308-00010 or

09308-10010 w/ output shaft installed

(b) Heat the extension housing end to 80 - 100°C(176 - 212°F) in an oil bath.

(c) Using SST, remove the bushing and install a new bushing.

SST 09307-30010

(d) Using SST, drive in a new oil seal. SST 09325-20010

Was this article helpful?

0 0
Simple Car Care Tips and Advice

Simple Car Care Tips and Advice

Put an End to All Your Car Troubles. Does Your Car Break Down Often? Are You Spending More On Fuel Than You Thought You Would? Is Maintaining Your Car Eating Into Your Budget? Make Your Car Last Longer with Some Simple Do It Yourself Tips.

Get My Free Ebook


Post a comment