Gear Components

INSPECTION

Gears and Shafts





Mainshaft and gear





Counter gear

- Check shafts for cracks, wear or bending.
- Check gears for excessive wear, chips or cracks.

Synchronizers





- Check spline portion of coupling sleeves, hubs, and gears for wear or cracks.
- Check baulk rings for cracks or deformation.
- Check shifting inserts for wear or deformation.
- Check insert springs for deformation.





- Measure wear of main drive, 1st and OD baulk rings.
Clearance between baulk ring and gear:
Refer to "Clearance Between Baulk Ring and Gear", under Manual Transmission/Transaxle; Specifications; Mechanical.
- If the clearance is smaller than the wear limit, replace baulk ring.





Inner baulk ring





Outer baulk ring

- Measure wear of 2nd and 3rd baulk rings.
a. Place baulk rings in position on synchronizer cone.
b. While holding baulk rings against synchronizer cone as far as it will go, measure dimensions "A" and "B".
Standard:
A 0.7 - 0.9 mm (0.028 - 0.035 inch)
B 0.6 - 1.1 mm (0.024 - 0.043 inch)
Wear limit: 0.2 mm (0.008 inch)
- If dimension "A" or "B" is smaller than the wear limit, replace outer baulk ring, inner baulk ring and synchronizer cone as a set.





- Measure wear of reverse baulk ring.
a. Place baulk ring in position on reverse cone.
b. While holding baulk ring against reverse cone as far as it will go, measure dimension "A" with dial indicator.
Dimension "A":
Standard -0.1 to 0.35 mm (-0.0039 to 0.0138 inch)
Wear limit 0.7 mm (0.028 inch)
c. If dimension "A" is larger than the wear limit, replace baulk ring.

Bearings





- Make sure bearings roll freely and are free from noise, cracks, pitting or wear.