SECONDARY SHAFT COMPONENTS INSPECTION

Gears Inspection

1. Inspect the synchronizer cones for wear.

• If there is malfunction, replace parts as necessary.

2. Inspect the gear teeth for damage, wear, and cracks.

• If there is malfunction, replace parts as necessary.

3. Inspect the synchronizer ring matching teeth for damage and wear.

• If there is malfunction, replace the synchronizer ring.

Synchronizer Ring Inspection

1. Inspect the synchronizer ring teeth for damage, wear, and cracks.

• If there is malfunction, replace parts as necessary.

2. Inspect the tapered surface for wear and cracks.

• If there is malfunction, replace parts as necessary.

3. Measure the clearance between the synchronizer ring and the side of gear circumferentially using a feeler gauge.

• If the clearance is exceed the minimum, replace the synchronizer ring.

Standard clearance

1.50 mm {0.059 in}

Minimum

0.80 mm {0.031 in}

Clutch Hub Component Inspection

1. Inspect the clutch hub sleeve and hub operation.

• If there is malfunction, replace parts as necessary.

2. Inspect the gear teeth for damage, wear, and cracks.

• If there is malfunction, replace parts as necessary.

3. Inspect the synchronizer keys for damage, wear, and cracks.

• If there is malfunction, replace parts as necessary.

4. Measure the clearance between the hub sleeve and shift fork.

• If the clearance exceeds the maximum, replace the hub sleeve and shift fork as a set.

Standard clearance

0.10-0.45 mm {0.004-0.017 in}

Maximum clearance

0.95 mm {0.037 in}

Secondary Shaft Gear Inspection

1. Inspect the gear contact surface for damage and wear.

• If there is malfunction, replace the secondary shaft.

2. Inspect the splines for damage and wear.

• If there is malfunction, replace the secondary shaft.

3. Inspect the gear teeth for damage, wear, and cracks.

• If there is malfunction, replace the secondary shaft.

4. Inspect the oil passage for clogging.

• If there is malfunction, replace the secondary shaft.

5. Measure the shaft gear runout.

• If not as specified, replace the secondary shaft.

Secondary shaft gear runout

0.015 mm {0.0006 in} max.

6. Measure the clearance between the shaft gears and the gears.

• If not as specified, replace parts as necessary.

mm{in}