SECONDARY SHAFT COMPONENTS INSPECTION

Secondary Shaft and Gear Inspection

1. Inspect the shaft for damage, abnormal wear, dents, flaking, or bending.

• If there is any malfunction, replace the shaft.

2. Inspect the gears for damage, abnormal wear, dents, flaking, or bending.

• If there is any malfunction, replace the gear.

3. Inspect the oil passage for clogging.

• If there is any malfunction, replace the shaft.

Synchronizer Ring and Clutch Hub Component Inspection

1. Inspect the clutch hub sleeve, clutch hub, and synchronizer key contact surface for damage and abnormal wear.

• If there is any malfunction, replace the part where necessary.

2. Verify that the clutch hub sleeve and clutch hub move smoothly.

• If there is any malfunction, replace parts if necessary.

3. Inspect the synchronizer ring teeth and grooves for damage, abnormal wear, and cracks.

• If there is any malfunction, replace the synchronizer ring.

4. Inspect the tapered surface for abnormal wear and cracks.

• If there is any malfunction, replace parts if necessary.

Synchronizer Ring Clearance Inspection

Synchronizer component (1st gear)

1. Measure the clearance of synchronizer component outer, middle and inner synchronizer rings.

• If clearances A and B less than the minimum specification, replace as a set.

(1) Measure clearance A in two places or more and on opposite sides using a dial gauge, and calculate the average value.

Clearance A

Standard: 0.60-0.80 mm {0.0236-0.0315 in}

Minimum: 0.20 mm {0.0079 in}

(2) Measure clearance B in two places or more and on opposite sides using a feeler gauge, and calculate the average value.

Clearance B

Standard: 0.60-1.10 mm {0.0236-0.0433 in}

Minimum: 0.20 mm {0.0079 in}

Synchronizer component (2nd gear)

1. Inspect clearance of the synchronizer component outer, middle, and inner synchronizer rings.

• If the clearance A, B and C less than the minimum specification, replace as a set.

(1) Measure clearance A in two places or more and on opposite sides using a feeler gauge while the synchronizer ring is manually press fit to the taper surface of the clutch gear, and calculate the average value.

Clearance A

Standard: 0.60-1.20 mm {0.0236-0.0472 in}

Minimum: 0.30 mm {0.0118 in}

(2) Measure clearance B in two places or more and on opposite sides with a feeler gauge, and calculate the average value.

Clearance B

Standard: 0.60-1.10 mm {0.0236-0.0433 in}

Minimum: 0.20 mm {0.0079 in}

(3) Measure clearance C in two places or more and on opposite sides with a feeler gauge while the synchronizer ring is manually press fit to the taper surface of the clutch gear, and calculate the average value.

Clearance C

Standard: 0.70-1.10 mm {0.0276-0.0433 in}

Minimum: 0.30 mm {0.0118 in}

Bearing Inspection

1. Inspect the ball and the ball contact surface for damage and abnormal wear.

• If there is any malfunction, replace the bearing.

2. Verify that the bearing rotates smoothly.

• If there is any malfunction, replace the bearing.