Inspection
INPUT SHAFT INSPECTIONINPUT SHAFT
Check the input shaft for damage, flaking, dents, uneven wear, bend, and other defects.
SPEED GEARS
1. Check the helical gear teeth and clutch gear teeth of each speed gear for damage and excessive wear.
2. Check the synchronizer cone surface of each speed gear for roughness, damage, and excessive wear (3rd gear excepted).
3. Check the inside surface and front and back sides of each speed gear for damage and excessive wear.
NEEDLE ROLLER BEARINGS
1. Combine each needle roller bearing with the input shaft, corresponding sleeve, and gear. Rotate the assembly, checking for smooth rotation, looseness, and noise.
2. Check the retainer for deformation.
SINGLE CONE SYNCHRONIZER RING
1. Check the clutch gear on the synchronizer ring for damaged and missing teeth.
2. Check the synchronizer ring inner cone surface for damage or wear. Also check that the inside ridges are intact.
3. Check the synchronizer key contact surfaces of the synchronizer ring for damage, and excessive wear.
4. Press the synchronizer ring against the cone of the adjacent speed gear, and check clearance A. Replace the synchronizer ring if the clearance is below the limit.
Limit: 0.7 mm (0.0276 inch)
DOUBLE CONE SYNCHRONIZER RING
1. Check the clutch gear on the outer synchronizer ring for damaged and missing teeth.
2. Check the contact surfaces between each synchronizer ring and synchronizer cone for damage and wear. Also check that the cone ridges are intact.
3. Check the synchronizer key contact surfaces of the outer synchronizer ring for damage and excessive wear.
4. Combine the synchronizer rings and synchronizer cone, and check clearances A and B shown in the illustration. Replace them if either of the clearances is greater than the limit.
Limit: 0.2 mm (0.0079 inch)
SYNCHRONIZER KEYS
Check the synchronizer hub contact surfaces of each synchronizer key for damage and excessive wear.
SYNCHRONIZER SPRINGS
Check the synchronizer springs for loss of tension, deformation, and breakage.