Remove Shifting Keys And Springs From Hub Sleeve Assembly

Using screwdriver, remove the three shifting keys and two springs.

HINT: No.1 hub sleeve and No.2 hub sleeve.

INSPECT OF OUTPUT SHAFT ASSEMBLY 1. MEASURE EACH GEAR THRUST CLEARANCE

(a) Using a feeler garge, 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:

Maximum clearance:

2nd and 3rd gear

Standard clearance:

Maximum clearance:

0.10 — 0.45 mm (0.0039 - 0.0177 in.) 0.50 mm (0.0197in.)

0.10 — 0.25 mm (0.0039 - 0.0098 in.) 0.30 mm (0.0118in.)

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.)

Shaft Runout

(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.

(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.

Measuring Sleeve Fork Clearance

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.

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