Part 4

151. Remove the 1st gear thrust washer (1) from the output shaft.




152. Remove the 1st gear thrust washer pin or ball (1) from the output shaft.





Note: Use a shop rag or piece of cloth to keep the shifting keys and shifting key springs from flying off.

153. Remove the reverse gear, synchromesh shifting keys, and synchromesh shifting key springs from the No. 1 transmission clutch hub.




154. Using a dial indicator and V-blocks, check the output shaft runout.

Maximum Runout - 0.015 mm (0.0005 in)
If the runout exceeds the maximum, replace the output shaft.




155. Using a micrometer, measure the outer diameter of the output shaft journal surface at the locations indicated.

* Standard Outer Diameter, Part 1 - 31.985-32.000 mm (1.2592-1.2598 in)
* Standard Outer Diameter, Part 2 - 37.985-38.000 mm (1.4955-1.4961 in)
* Standard Outer Diameter, Part 3 - 32.985-33.000 mm (1.2986-1.2992 in)

156. If any of the outer diameters are less than the minimum, replace the output shaft.




157. Using a cylinder gage, measure the inside diameter of the 2nd gear.

* Standard Inside Diameter - 38.015-38.031 mm (1.4967-1.4972 in)
* Maximum Inside Diameter - 38.031 mm (1.4972 in)

158. If the inside diameter exceeds the maximum, replace the 1st gear.
159. Using a cylinder gage, measure the inside diameter of the 1st gear.

* Standard Inside Diameter - 44.015-44.031 mm (1.7328-1.7335 in)
* Maximum Inside Diameter - 44.031 mm (1.7335 in)

160. If the inside diameter exceeds the maximum, replace the 1st gear.




161. Using a micrometer, measure the 1st gear thrust washer.

* Standard Thickness - 5.975-6.025 mm (0.2352-0.2372 in)
* Minimum Thickness - 5.975 mm (0.2352 in)

162. If the thickness is less than the minimum, replace the 1st gear thrust washer.




163. Coat the 2nd gear cone and No. 2 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.
164. Install the inner ring onto the 2nd gear.




165. Install the middle ring onto the 2nd gear.




166. Install the outer ring onto the 2nd gear.




167. Check for wear and damage.
168. Turn the synchronizer ring set in one direction while pushing it against the 2nd gear cone.
169. Check that the ring set locks.
If the synchronizer ring set does not lock, replace the synchronizer ring set.




170. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end.

* Standard Clearance - 0.60-1.40 mm (0.0236-0.0551 in)
* Minimum Clearance - 0.60 mm (0.0236 in)

171. If the clearance is less than the minimum, replace the synchronizer ring set.




172. Coat the 1st gear cone and No. 1 synchronizer ring set (inner ring, middle ring, and outer ring) with gear oil.
173. Install the inner ring onto the 1st gear.




174. Install the middle ring onto the 1st gear.




175. Install the outer ring onto the 1st gear.




176. Check for wear and damage.
177. Turn the synchronizer ring set in one direction while pushing it against the 1st gear cone.
178. Check that the ring set locks.
If the synchronizer ring set does not lock, replace the synchronizer ring set.




179. Using a feeler gage, measure the clearance between the synchronizer ring and the gear spline end.

* Standard Clearance - 0.60-1.40 mm (0.0236-0.0551 in)
* Minimum Clearance - 0.60 mm (0.0236 in)

180. If the clearance is less than the minimum, replace the synchronizer ring set.




181. Remove the speedometer drive gear from the front differential case.




182. Place matchmarks (1) on the front differential ring gear and the front differential case.




183. Remove the bolts (1-6).
184. Using a plastic hammer, remove the front differential ring gear from the front differential case.




185. Fix the front differential pinion to the front differential case side. Using a dial indicator, measure the front differential side gear backlash.

Standard Backlash - 0.05 to 0.20 mm (0.0020 to 0.0079 in)

186. If the backlash is out of the specification, replace the side gear thrust washers.




187. Using a chisel and a hammer, loosen the staked part of the front differential case.




188. Using a pin punch (3 mm) and a hammer, remove the front differential pinion shaft straight pin from the front differential case.




189. Remove the front No. 1 differential pinion shaft from the front differential case.





Note: While rotating the front differential pinion, remove the pinions and side gears.

190. Remove the front differential pinions, front differential pinion thrust washers, No. 1 front differential side gear thrust washers, and front differential side gears from the front differential case.




191. Using a micrometer, measure the thickness of the front differential pinion thrust washer.

Minimum Thickness - 0.94 mm (0.0370 in)

192. If the thickness is less than the minimum, replace the front differential pinion thrust washer.




193. Using a micrometer, measure the outer diameter of the front No. 1 differential pinion shaft.

Minimum Outer Diameter - 16.982 mm (0.6685 in)

194. If the outer diameter is less than the minimum, replace the front No. 1 differential pinion shaft.